6/26/2003 foamlogix - montgomery county, md...to small leads that are supplying some other device...

6/26/2003

HALE PRODUCTS, INC. � A Unit of IDEX Corporation � 700 Spring Mill Avenue � Conshohocken, PA 19428 � TEL: 610-825-6300 � FAX: 610-825-6440

MANUAL P/N 029-0020-68-0, REV B, © 2003 HALE PRODUCTS, INC., PRINTED IN U.S.A.

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Hale Products cannot assume responsibility for product failure resulting from impropermaintenance or operation. Hale Products is responsible only to the limits stated in the productwarranty. Product specifications contained in this material are subject to change without notice.

All Hale products are quality components: ruggedly designed, accurately machined, precision inspected, carefully assembledand thoroughly tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important tofollow 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.

DESCRIPTION, INSTALLATION ANDOPERATION MANUAL

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Hale FoamLogix System Serial Number: _____________________________Date Unit Placed in Service: _______________________________________Fire Department: ________________________________________________Engine Number: ________________________________________________Calibration Factors:

Water Flow Factor: __________________________________________Class A Foam Factor:________________________________________Class B Foam Factor: _______________________________________

NOTICE: This manual is divided into four sections for clarity and ease of use. Section �: DESCRIPTION; Provides anintroduction to the Hale foam proportioning system along with guidelines for designing and ordering a completesystem. Section ��: INSTALLATION; Provides information to assist the OEM with installation and initial set-up of Hale foamproportioning systems on an apparatus. Section ��: SET-UP AND CALIBRATION; Is used by the installer and end user forstart-up and calibration of the Hale foam proportioning system. Section ��: OPERATION; Is primarily used by theapparatus user for proper operation and maintenance of the Hale foam proportioning system. Each manual sectioncan be a stand alone section or can be used in conjunction with each other.

FoamLogix��

Description, Installation and Operation Manual i

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TABLE OF CONTENTSChapter Title PageSECTION �: DESCRIPTION

SAFETY .................................................................................................................................... �-1SYSTEM DESCRIPTION ............................................................................................................ �-3SYSTEM SPECIFICATIONS ....................................................................................................... �-6SYSTEM CONFIGURATION ..................................................................................................... �-8SYSTEM DIAGRAMS ............................................................................................................. �-16

SECTION ��: INSTALLATIONSAFETY ................................................................................................................................... ��-1APPARATUS INSTALLATION PLANNING ............................................................................... ��-3INSTALLER SUPPLIED COMPONENT RECOMMENDATIONS ............................................... ��-5FOAM PUMP MOUNTING..................................................................................................... ��-9PLUMBING COMPONENT INSTALLATION.......................................................................... ��-12SYSTEM PLUMBING DIAGRAMS ......................................................................................... ��-24ELECTRICAL INSTALLATION ................................................................................................ ��-33SYSTEM ELECTRICAL DIAGRAMS ....................................................................................... ��-43START-UP CHECKLIST .......................................................................................................... ��-45SYSTEM INSTALLER START-UP .............................................................................................. ��-46

SECTION ��: SET-UP AND CALIBRATIONSAFETY .................................................................................................................................. ��-1INSTALLATION AND DELIVERY CHECKLIST ......................................................................... ��-3INITIAL END USER SET-UP...................................................................................................... ��-4USER CALIBRATION.............................................................................................................. ��-6

SECTION ��: SYSTEM OPERATIONSAFETY .................................................................................................................................. ��-1OPERATING INSTRUCTIONS ................................................................................................ ��-3

Normal Operation Summary ....................................................................................... ��-8Simulated Flow Operation ......................................................................................... ��-10Tank Selection With Dual Tank System ..................................................................... ��-12Flushing Hale FoamLogix ............................................................................................ ��-13Operation with Remote ON/OFF Switch .................................................................. ��-14Priming The Foam Pump When Foam Tank Has Run Dry ....................................... ��-14

MAINTENANCE .................................................................................................................. ��-15TROUBLESHOOTING .......................................................................................................... ��-16PARTS IDENTIFICATION ...................................................................................................... ��-22WARRANTY ......................................................................................................................... ��-28

System installer must provide two copies of this Hale Foam System Description, Installation andOperation Manual to the end user of the equipment. If additional manuals are required, contactHale Products Inc. Communications Department at (610) 825-6300.Ask for Manual P/N 029-0020-68-0.




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SECTION IDESCRIPTION

NOTICE: This manual section provides a general description of the Hale foam proportioningsystem along with guidelines for designing and ordering a complete system. This manual sectioncan be used as a stand alone section or in conjunction with other sections of the completemanual.

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Section �: Description

SAFETYHale Foam systems are designed to provide reliable and safe foam concentrate injection.Before installing or operating a Hale Foam system read all safety precautions and followcarefully to ensure proper installation and personnel safety.

WARNINGS1. Do not permanently remove or alter any

guard or insulating devices or attempt tooperate the system when these guardsare temporarily removed.

2. To prevent electrical shock alwaysdisconnect the primary power sourcebefore attempting to service any part ofthe Hale Foam system.

3. All electrical systems have the potentialto cause sparks during service. Takecare to eliminate explosive or hazardousenvironments during service/repair.

4. To prevent system damage or electricalshock the main power supply wire will bethe last connection made to the HaleFoam proportioner distribution box.

5. Release all pressure then drain allconcentrate and water from the systembefore servicing any of its componentparts.

6. Rotating drive line components cancause injury. When working oncomponents of the Hale Foam systembe careful of rotating components.

CAUTIONS1. Foam tank low level sensors must be

utilized to protect the Hale Foamproportioner from dry running. Failure touse low level sensors with the Hale Foamsystem will void warranty.

2. Do not operate system at pressureshigher than the maximum ratedpressure.

3. Use only pipe, hose, and fittings from thefoam pump outlet to the injector fitting,which are rated at or above themaximum pressure rating at which thewater pump system operates.

4. Hale Foam proportioning systems aredesigned for use on negative grounddirect current electrical systems only.

5. Do not mount radio transmitter ortransmitter cables in direct or closecontact with the FoamLogix control unit.

6. Before connecting the cordsets andwiring harnesses inspect the seal washerin the female connector. If the sealwasher is missing or damaged, watercan enter the connector causingcorrosion of the pins and terminalsresulting in possible system failure.

7. Always disconnect the power cable,ground straps, electrical wires andcontrol cables from the control unit orother Hale Foam system equipmentbefore electric arc welding at any pointon the apparatus. Failure to do so couldresult in a power surge through the unitthat could cause irreparable damage.

8. DO NOT connect the main power leadto small leads that are supplying someother device such as a light bar or siren.The Hale FoamLogix Model 3.3 andModel 5.0 require 60 AMP minimumcurrent.

9. When operating the Hale FoamLogix inSimulated Flow mode an outlet for thefoam concentrate must be provided toprevent excessive pressure buildup indischarge piping or hoses.

10. Unless engaged in Class B foamoperations, the ADT toggle switch orMDT II selector handle must be in theTANK A or FLUSH position. If the toggleswitch or selector handle is in the FLUSHposition when the Hale Foam systemfoam pump is started the foam pumpwill only run for 20 seconds and shutdown.

11. Make sure the foam tank and foamconcentrate suction hoses are cleanbefore making final connection to foampump. If necessary flush tank and hosesprior to making connection.

Ι−2 Section �: Description

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NOTES1. Check all hoses for weak or worn

conditions after each use. Ensure thatall connections and fittings are tight andsecure.

2. Ensure that the electrical source ofpower for the unit is a negative groundDC system, of correct input voltage, witha reserve minimum current available todrive the system.

3. The in-line strainer/valve assembly is alow pressure device and WILL NOTwithstand flushing water pressure. Wheninstalling the in-line strainer in systemsequipped with Hale MDT ΙΙ or Hale MSTmake sure the in-line strainer/valveassembly is in the hose on the inlet sideof the valve. If the strainer will besubject to flushing water pressure, useHale FS series strainers.

4. When determining the location of HaleFoam system components keep in mindpiping runs, cable routing and otherinterferences that will hinder or interferewith proper system performance.

5. Always position the check valve/injectorfitting at a horizontal or higher angle toallow water to drain away from thefitting. This will avoid sediment depositsor the formation of an ice plug.

6. The cordsets provided with each HaleFoam system are 100% electricallyshielded assemblies. Never attempt toshorten or lengthen the molded cables.If necessary order longer or shortercordsets from Hale Products to suit theparticular installation.

7. The cordsets provided with each HaleFoam system are indexed so they onlygo in the correct receptacle and theycan only go in one way. When makingcordset connections DO NOT forcemismatched connections as damagecan result in improper system operation.

8. The system can only perform when theelectrical connections are sound, so

make sure each one is correct.9. The cables shipped with each Hale

Foam system are 100% tested at thefactory with that unit. Improperhandling and forcing connections candamage these cables which could resultin other system damage.

10. There are no user serviceable partsinside Hale Foam system electrical/electronic components. Opening ofthese components (distribution box,control unit, foam discharge multiplexingdisplay unit) will void warranty.

11. Use mounting hardware that iscompatible with all foam concentratesto be used in the system. Use washers,lockwashers and capscrews made ofbrass or 300 series stainless steel.

12. When making wire splice connectionsmake sure they are properly insulatedand sealed using an adhesive filled heatshrink tubing.

13. Before running wires from the low tankswitches to the A-B switch box make surethe wire from Tank A is identified andproperly labeled.

14. ALWAYS connect the primary positivepower lead from the terminal block tothe master switch terminal or the positivebattery terminal using minimum 4 AWGtype SGX (SAE J1127) chemical resistantbattery cable and protect with wireloom.

15. Prevent corrosion of power and groundconnections by sealing theseconnections with silicone sealantprovided.

16. Prevent possible short circuit by using therubber boot provided to insulate theprimary power connection at the HaleFoamLogix distribution box.

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SYSTEM DESCRIPTIONoperating. The control unit display alsowarns the operator when errors orabnormal operations occur in the system.

Foam concentrate injection rate iscontrolled by a computer chip in thecontrol unit for accurate, repeatable,reliable foam concentrate injection. Awater flowsensor constantly monitors waterflow through the discharge piping. Theinformation from the flowsensor is providedto the control unit by a shielded cable.When the Hale Foam system is activated atthe control unit a signal is sent from thecontrol unit through the shielded controlcable to the distribution box to begin foamconcentrate injection. The distribution boxthen provides power to the electric motor.As the motor rotates the pump, foamconcentrate flows through the foam pumpdischarge to the one piece check valve/injector fitting into the water dischargestream.

A feedback sensor in the foam pump bodymeasures foam concentrate flow. Thewater flow rate and foam concentrate flowrate are constantly compared by thecomputer chip in the control unit. Themotor speed is constantly adjusted tomaintain the operator selected foamconcentrate injection rate. Since thesystem is flow based, injection rate remainsconstant regardless of changes in systempressure or the number of discharges open.

There are two models of Hale Foam systemscovered by this manual. The HaleFoamLogix Model 3.3 and Model 5.0. Themaximum rated foam concentrate flow ingallons per minute is denoted by the modelnumber. Table 1 shows system capacitiesat various foam concentrate injection ratesfor the different Hale Foam Models.

Hale Foam systems can be configured tooperate with single or dual foam

Hale Foam proportioning systems arecompletely engineered, factory matchedfoam proportioning systems that providereliable, consistent foam concentrateinjection for Class A and Class B foamoperations. Hale FoamLogix Foam systemsaccurately deliver from 0.1% to 10.0% foamconcentrate through a check valve/injector fitting directly into the waterdischarge stream. It is then fed as foamsolution into a standard fog nozzle, an airaspirated nozzle, or CAFS equipment,through the apparatus discharge piping. Aproperly configured and installed foamsystem with Hale recommendedcomponents virtually eliminatescontamination of the booster tank, firepump and relief valve with foamconcentrate.

The heart of the Hale Foam system is anelectric motor driven rotary gear pump.The pump is constructed of bronze andstainless steel and is compatible with almostall foam concentrates. The pump is closecoupled to the electric motor therebyeliminating maintenance of an oil filledgearbox. An internal relief valve,constructed of stainless steel, protects thefoam pump and foam concentratedischarge hoses from overpressurizationand damage.

The control unit, mounted on the operatorpanel, is the single control point for the HaleFoam system. Depressing the ON buttonstarts foam concentrate injection. A superbright digital LED display shows the waterflow rate, total water flowed, foamconcentrate injection percentage andtotal foam concentrate used depending onthe display mode selected. A bargraph onthe control unit provides indication of theapproximate system capacity being used.Adjustment of foam concentrate injectionrate can be accomplished by pushing theappropriate button while the system is


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concentrate tanks. Examples of the variousHale Foam system configurations are shownin figures 1-1 through 1-7 at the end of thissection.

The available Air Dual Tank (ADT) valve forthe Hale Foam system is an air operatedfoam tank selector valve that providesselection of foam concentrate dependenton fire ground operational demands. TheADT is an integral part of the foam pumpand provides an electrical interlock for thelow tank level sensors and concentrateinjection rate. A panel mounted selectortoggle switch with indicator lights controlsfoam concentrate tank selection and showswhich foam concentrate tank is in use.

The Manual Dual Tank (MDT ΙΙ) selectorvalve is available for the Hale Foam systemswith dual tanks. The MDT ΙΙ is a panelmounted manually operated selector thatprovides selection of foam concentratedependent on fire ground operationaldemands. The MDT ΙΙ also provides anelectrical interlock for the low tank levelsensors and concentrate injection rate. Itshould be noted that the MDT ΙΙ is notsuitable for top mount operator panelinstallations and some side operator panelsdue to gravity feed requirements of foamconcentrate to the foam pump.

Selection of the desired foam concentratetank with the ADT panel mounted toggleswitch or MDT ΙΙ selector will automatically

change the foam concentrate injectionrate to the preset default rate for theselected foam tank. No further operatorintervention is required.

Single tank foam systems can beconfigured with a Manual Single Tank (MST)selector which provides a flush functionconnection to the foam system electroniccontrols.

The ADT, MDT ΙΙ and MST all provide thecheck valves and connection points toprovide foam pump flushing capabilities.

Strainers available for Hale FoamLogix Foamsystems protect the foam pump from debristhat might accumulate in the foamconcentrate tank. The standard in-linestrainer/valve assembly has a compositenonmetallic housing with stainless steelmesh strainer element. It is provided with aservice shutoff valve, mounting bracket.The strainer and valve have 1-1/4 NPTthreads and is supplied with fittings forconnection of either 1-1/4 inch (32 mm) ID,1 inch (25 mm) ID or ¾ inch (19 mm) IDfoam concentrate suction hose. The in-linestrainer/valve assembly is suitable for usewith both Class A and Class B foamconcentrates. The in-line strainer/valveassembly is designed for installations wherethe strainer is mounted in the foam pumpsuction line and IS NOT subject to flushingwater pressure.

Hale FS series strainers are panel mountedstrainers with a 500 PSIG (34 BAR) pressurerating suitable for use where flushing waterpressure will go through the strainer. TheFS15 strainer has ¾ inch NPT connectionports and a 1-½ inch NST cap and is suitablefor use with Class A and low viscosity Class Bfoam concentrates. The FS25 strainer has 1inch NPT connection ports and a 2-½ inchNST cap and is suitable for use with bothClass A and Class B foam concentrates.

All Hale FoamLogix Foam systems require aflowsensor for operation.

WATER FLOWMODEL 3.3 MODEL 5.0

FOAMCONCENTRATE

(%)

0.10.20.30.5136

GPM LPM

3300 124911650 62451100 4164660 2498330 1249110 41655 208

GPM LPM

5000 189252500 94631667 63101000 3785500 1893167 63283 314

Table 1. Maximum Foam Solution Flows

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Ordering of Hale Foam systems is simple.Using the current Hale FoamLogix FoamSystem Price List and Order Form helpsensure a complete matched system isprovided to the end user.

Use the following procedure when orderinga Hale FoamLogix Foam system. Followingall the steps ensures a complete system willbe ordered:

1. Check Hale Foam system productinformation update (Bulletin 961) for thelatest information and advice for foamsystem selection.

2. Determine the type of foamconcentrate to be used in the systemand ensure system compatibility byreferring to the Hale Foam ConcentrateCompatibility list (Bulletin #650).

3. Determine the Hale Foam systemdesired (Model 5.0 or Model 3.3; 12 VDCor 24 VDC motor).

4. Determine tank selector desired basedon the number of foam concentratetanks installed (ADT or MDT ΙΙ for dualtank systems; MST or No Selector forsingle tank systems).

5. Determine strainers desired (In-lineStrainer/Valve Assembly, FS 15 Straineror FS 25 Strainer).

6. Determine the low tank level sensorsdesired (Side Mount, Bottom Mount orTop Mount Assembly).

7. Select the flowsensor then the mountingweld fitting or saddle clamp based ondischarge pipe size. Select flowsensorcable length (10 feet, 20 feet or 30 feet).

8. Determine additional Hale componentsthat enhance system operation andease installation (Control CableExtension, Waterway Check Valves,Manifolds, Flanges, etc.).

Components shown in Bold type aboverepresent the best value performancesystem. System components are shown inthe following system configuration section.All components listed have beenengineered and tested with Hale Foamsystems to provide optimum systemperformance. Using the informationprovided in this manual section and thedetailed ordering procedures on the optionorder form ensures a complete Hale Foamsystem is ordered thus eliminating delayscaused by missing components.


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Foam Pump Installation Envelope DimensionsConfigured for use with MDT ΙΙ , MST or No Tank Selector Option

¾ INCH NPT SUCTIONHOSE CONNECTION

½ INCH NPT INJECTHOSE CONNECTION

½ INCH NPT BYPASS HOSECONNECTION

6.02 IN.(153 MM)

HALE FOAM SYSTEM SPECIFICATIONSFoam Pump................................................................................. Rotary Gear Positive DisplacementRated Foam Concentrate Output

Model 3.3 ........................................................................................................ 3.3 GPM (12 LPM)Model 5.0 ........................................................................................................ 5.0 GPM (19 LPM)

Maximum System Operating PressureModel 3.3 ......................................................................................................... 400 PSI (28 BAR)Model 5.0 ......................................................................................................... 250 PSI (17 BAR)

Maximum Operating Temperature ................................................................................. 160OF (71 C)Pump Motor.................................................................................¾ HP (0.5 kW), 12 VDC (Standard)

¾ HP (0.5 kW), 24 VDC (Optional)Operating Ampere Draw ...............................................30 AMPS @ 12 VDC (15 AMPS @ 24 VDC)Maximum Ampere Draw ...............................................60 AMPS @ 12 VDC (30 AMPS @ 24 VDC)

2.58 IN.(66 MM)

MODEL 5.0: 22.00 IN. (559 MM)MODEL 3.3: 21.75 IN. (552 MM)MODEL 5.0: 19.07 IN. (484 MM)MODEL 3.3: 18.82 IN. (478 MM)

9.43 IN.(240 MM)

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MODEL 5.0: 21.88 IN. (555 MM)MODEL 3.3: 21.63 IN. (549 MM)

Foam Pump Installation Envelope Dimensions Configured with Optional ADT

6.02 IN.(153 MM)

3.02 IN.(77 MM)

0.87 IN. (22 MM)TO CENTER OF FLUSH

WATER INLET CONNECTION

FLUSH WATER CONNECTION½ INCH NPT

TANK B CONNECTION1 INCH I.D. HOSE

BYPASS HANDLE: BYPASS POSITION

BYPASS HANDLE: INJECT POSITION

INJECT PORT: ½ INCH NPT

BYPASS PORT: ½ INCH NPT

TANK A CONNECTION¾ INCH I.D. HOSE

4.76 IN.(121 MM)

8.95 IN.(227 MM)

6.20 IN.(157 MM)

3.70 IN.(94 MM)

MODEL 5.0: 25.37 IN. (644 MM)MODEL 3.3: 25.12 IN. (638 MM)MODEL 5.0: 24.74 IN. (628 MM)MODEL 3.3: 24.94 IN. (622 MM)MODEL 5.0: 23.70 IN. (602 MM)MODEL 3.3: 23.45 IN. (596 MM)




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SYSTEM CONFIGURATION

Hale Foam Proportioner System Model(Model 3.3 or Model 5.0)

All Hale Foam systems include: Foam Pump/Motor Assembly, Control Unit, Control Cableand Check Valve/Injector Fitting

Foam Pump/Motor Assembly(Shown with Bypass Valve when configured for MDT ΙΙ , MST or no tank selector option)

Control UnitP/N 107064

Optional 6-Pin Extension Cable16.5 Feet (P/N 013-2020-05-0)6.5 Feet (P/N 013-2020-02-0)

Check Valve/Injector FittingP/N 038-1790-00-0

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Foam Pump/Motor Assembly with Air Dual Tank (ADT) Selector(P/N 538-1640-02-0)

Manual Dual Tank (MDT ΙΙ ) Selector and Wiring Harness(P/N 538-1490-11-0)

Dual Foam Concentrate Tank System Options

Dual Tank Instruction Placard/SystemDiagram (P/N 101-1631-07-0)

Panel Switch/IndicatorLight Placard Assembly

Optional Color Coded AirConnection Harness(P/N 507-0380-00-0)

MDT ΙΙ Wiring Harness Extension(P/N 513-0320-02-0)


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Foam Concentrate Strainers

FS-15 STRAINER (P/N 510-0150-00-0)(¾ Inch NPT Threads. Use With Class A

and thin Class B Foam Concentrates)

FS-25 STRAINER (P/N 510-0180-00-0)(1 Inch NPT Threads. Use With Class A

and Class B Foam Concentrates)

In-Line Strainer/Valve Assembly (P/N 510-0190-01-0)(Do Not Use If Subject to Flushing Water Pressure)

Hale FS Series Strainers (Use When Strainer is Subjected to Flushing Water Pressure)

Manual Single Tank (MST) SelectorProvides FoamPump Flushing Capabilities for a Single Tank System

(P/N 538-1490-12-0)

Single Foam Concentrate Tank Options

Single Tank Instruction Placard/SystemDiagram

(P/N 101-1631-12-0)

MST Wiring Harness(P/N 513-0320-04-0)

MST Wiring Harness Extension72 inches (1829 mm) long

(P/N 513-0320-07-0)

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Side Mount Low Tank Level Sensor(P/N 200-2110-02-0)

(½ Inch NPT Threaded Bushing to MountFrom Outside Foam Tank)

Low Tank Level Sensor Options(One Low Tank Level Sensor is Required for Each Foam Tank)

Brass Bottom Mount Low Tank LevelSensor

(P/N 200-2110-04-0)(1 Inch NPT Threaded Bushing to Mount

From Outside Foam Tank)Top Mount Low Tank Level Sensor

Assembly(P/N 200-2110-06-0)

(Extends From 2-½ Feet to 5 Feet Long.May be Cut Shorter)


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FlowsensorsEach Hale foam system requires a flowsensor to operate. Pipe size must be selected basedon the minimum and maximum water flow in the foam capable discharge. Following is alist of pipe size and rated flow range along with flowsensor saddle clamp part number: Inall instances a weld fitting may be substituted for the saddle clamp.

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The check valve manifolds include Flowsensor, Check Valve/Injector fitting and single ordual waterway check valve flappers. End connections for the manifolds are 3 inch victaulic.

Check Valve Manifolds

Remote Activation Switch(P/N 513-0330-01-0)

Remote Activation Switch Cable16 Feet (P/N 513-0680-00-0)

Remote Activation Switch

4-Pin Extension Cable6 Feet (P/N 013-2010-02-0)

16 Feet (P/N 013-2010-05-0)32 Feet (P/N 013-2010-10-0)


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3 Inch "115" Check Valve(P/N 038-1570-00-0)

4 Inch "2433D" Check Valve(P/N 038-1570-04-0)

Type 2433D FlangeUse 4 inch NPT with 4 inch check valves.

Also available with 2-½ and 3 inch NPT threads.

Type 115 FlangeUse 3 and 2-½ inch NPT with 3 inch check valves.Also available with 1-½ and 2 inch NPT threads.

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115 GASKET(P/N 046-0050-00-0)

2433D GASKET(P/N 046-0040-00-0)

Check Valves, Flanges and Gaskets

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Close Fit Flanged Elbow(P/N 098-0140-00-0)

115 flange inlet with 3 inch Victaulic outlet.


2433D flange inlet with 3 inch female NPTand 4 inch Victaulic outlet.


115 flange inlet with 2-½ inch female NPT outlet.


115 flange inlet with 115 flange outlet.

Mini Manifold(P/N 178-0320-02-0)

Elbows and Mini Manifold

INLET

OUTLET

FOAMINJECTION

OUTLET

OUTLET

OUTLET


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Figure 1-1. Hale Foam System Layout with Single Foam Concentrate Tank

CONTROLUNIT

DISTRIBUTIONBOX

FLOWSENSORCORDSET

BYPASSVALVE

FOAMINJECTION

HOSE

BYPASSHOSE

WATERWAYCHECKVALVE

IN-LINE FOAM STRAINER/VALVE ASSEMBLY

CONTROLCORDSET

WATERWAYCHECKVALVE

HALEFLOWSENSOR

PADDLE WHEELMOUNTED IN

SADDLECLAMP

CHECK VALVEINJECTOR

FITTING

FOAM SOLUTIONDISCHARGE(S)

FIREPUMP

FOAMTANK

FOAM TANKDRAINVALVE

SIDE MOUNT FOAMTANK LOW LEVELSENSOR OPTION

TOP MOUNT FOAMTANK LOW LEVELSENSOR OPTION

BOTTOM MOUNT FOAMTANK LOW LEVELSENSOR OPTION

FLUSHINGWATER SUPPLY

FOAM PUMP ANDMOTOR

ASSEMBLY

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Figure 1-2. Hale Foam System Layout with Single Foam Concentrate Tank, MST and In-line Strainer/Valve Assembly

FOAMTANK

FOAM TANKDRAINVALVE

MSTSELECTOR

VALVE




DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVEWATERWAY

CHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLY

CONTROLCORDSET


CONTROLUNIT


CHECK VALVEINJECTOR

FITTING


HALEFLOWSENSOR


SADDLECLAMP


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FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLY

CONTROLCORDSET


FS-15 OR FS-25 PANELMOUNTED FOAM

STRAINER

FOAMTANK

FOAM TANKDRAINVALVE

FOAM TANKSHUTOFF

VALVE

MSTSELECTOR

VALVE

CONTROLUNIT

FLUSHINGWATER SUPPLY CHECK VALVE

INJECTORFITTING

Figure 1-3. Hale Foam System Layout with Single Foam Concentrate Tank, MST and FSSeries Strainer

HALEFLOWSENSOR


SADDLECLAMP

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FOAMTANK B

FOAMTANK A

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

MDT ��SELECTOR

VALVE






FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLYCONTROLCORDSET


CONTROLUNIT


CHECK VALVEINJECTOR

FITTING



Figure 1-4. Hale Foam System Layout with Dual Foam Concentrate Tanks, MDT ΙΙ and In-line Strainer/Valve Assembly

HALEFLOWSENSOR


SADDLECLAMP


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FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLYCONTROLCORDSET



FS-15 OR FS-25 PANELMOUNTED FOAM

STRAINER

FOAMTANK B

FOAMTANK A

FOAM TANKSHUTOFF

VALVE FOAM TANKDRAIN VALVE FOAM TANK

DRAIN VALVE

FOAM TANKSHUTOFF

VALVE

MDT ��SELECTOR

VALVE

CONTROLUNIT


CHECK VALVEINJECTOR

FITTING






Figure 1-5. Hale Foam System Layout with Dual Foam Concentrate Tanks, MDT ΙΙ and FSSeries Strainer Assembly

HALEFLOWSENSOR


SADDLECLAMP

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FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP

FOAM PUMPWITH ADT

CONTROLCORDSET


ADTSELECTOR

SWITCH ANDINDICATOR

LIGHTS

CONTROLUNIT


CHECK VALVEINJECTOR FITTING

FOAMTANK B

FOAMTANK A

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE



Figure 1-6. Hale Foam System Layout with Dual Foam Concentrate Tanks, ADT and In-line Strainer/Valve Assemblies

HALEFLOWSENSOR


SADDLECLAMP


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FLOWSENSORCORDSET DISTRIBUTION

BOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP

FOAM PUMPWITH ADT

CONTROLCORDSET


FS-15 PANELMOUNTED FOAM

STRAINER

FS-25 PANELMOUNTED FOAM

STRAINER

FOAMTANK B

FOAMTANK A

FOAM TANKSHUTOFF

VALVE

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

FOAM TANKSHUTOFF

VALVE

ADTSELECTOR

SWITCH ANDINDICATOR

LIGHTSCONTROLUNIT


CHECK VALVEINJECTOR

FITTING

Figure 1-7. Hale Foam System Layout with Dual Foam Concentrate Tanks, ADT and FSSeries Strainer Assemblies

HALEFLOWSENSOR


SADDLECLAMP




FoamLogix��

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SECTION IIINSTALLATION

NOTICE: This manual section provides information to assist the OEM with installation and initial set-up of Hale foam proportioning systems on an apparatus. This manual section can be used as astand alone section or in conjunction with other sections of the complete manual.

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Section ��: Installation

SAFETYHale FoamLogix systems are designed to provide reliable and safe foam concentrateinjection. Before installing or operating a Hale FoamLogix system read all safetyprecautions and follow carefully to ensure proper installation and personnel safety.













5. Do not mount radio transmitter ortransmitter cables in direct or closecontact with the FoamLogix control unit.







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8. The system can only perform when theelectrical connections are sound, somake sure each one is correct.

9. The cables shipped with each HaleFoam system are 100% tested at the

factory with that unit. Improperhandling and forcing connections candamage these cables which could resultin other system damage.

10. There are no user serviceable partsinside Hale Foam system electrical/electronic components. Opening ofthese components (distribution box,control unit, foam discharge multiplexingdisplay unit) will void warranty.







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APPARATUS INSTALLATION PLANNING(ADT valve is an optional part of foampump)Manual dual tank (MDT ΙΙ) selector valveManual single tank (MST) selector valveMini ManifoldFlanged elbowsFoam tank(s)Remote activation switch

IMPORTANT: When determining thelocations of Hale FoamLogixcomponents being installed keep inmind piping runs, cable routing andother interferences that will hinder orinterfere with proper systemperformance.

FOAM PUMP and MOTOR ASSEMBLY: Ideallythe foam pump and motor assembly shouldbe located in an area that is protectedfrom road debris and excessive heatbuildup. The foam system master powerswitch and bypass valve are located on thefoam pump and motor assembly andaccess to these controls must be provided.It is recommended that the foam pumpand motor assembly be located in aprotected area but, foam concentrategravity feed requirements or apparatusdesign limitations may necessitate locatingthe foam pump and motor assembly on ashelf in the apparatus pump house orattached to the apparatus frame.

The foam pump and motor assembly shouldbe mounted below the discharge of thefoam tank(s) to provide for gravity feed tothe foam pump. The foam tank(s) must belocated where refilling can be easily donewith 5 gallon (19 liter) pails and othermethods suitable to the end user. Mostwater tank manufacturers will build foamtanks into the booster tank. Whenspecifying foam tank(s) make sureprovisions are made for installation of thelow tank level sensor as well as foam suction

Differences in apparatus plumbing andfoam system configuration make itimpractical to show exactly how each HaleFoamLogix system is installed on a particularapparatus. The information contained inthis section, however, will apply to mostsituations and should be used whendesigning and installing a Hale FoamLogixsystem. System plumbing and electricaldiagrams are provided at the end of thisinstallation section to assist the apparatusmanufacturer with installation of the HaleFoamLogix system.

The following subsections provide thesystem installer with guidelines for acomplete system installation. Beforeproceeding with system installation carefullyreview the procedures that follow to ensurethe system is properly designed. Thesubsection titled Installer SuppliedComponent Recommendations lists thosecomponents that have been tested withHale FoamLogix and provide the bestsystem performance. Use of therecommended materials and specifiedparts will ensure a virtually maintenancefree installation.

The Hale FoamLogix system is supplied withsix major components that must be locatedon the apparatus. The major componentsof the Hale FoamLogix system are:

Foam pump and motor assemblyControl unitIn-Line foam strainer/valve assemblyInstruction/system diagram placardFlowsensorCheck valve injector fitting

Optional components to enhance systeminstallation and operation that requiremounting on the apparatus include:

FS15 or FS25 panel mounted foamstrainerADT operating switch and indicator lights

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connections, tank drainage and proper fillopenings per NFPA requirements.

FOAM CONCENTRATE STRAINER: Determinea location on the apparatus to mount thefoam strainer.

CAUTION: The in-line strainer/valveassembly is a low pressure device andWILL NOT withstand flushing waterpressure. When installing the in-linestrainer in systems equipped with HaleMDT ΙΙ or Hale MST make sure the in-linestrainer/valve assembly is in the hose onthe inlet side of the valve. If the strainerwill be subject to flushing water pressure,use Hale FS series strainers.

Mount the in-line foam strainer/valveassembly in the foam concentrate hosefrom the foam tank to the foam pumpsuction connection, ADT, MDT ΙΙ or MST.When determining the strainer locationkeep in mind the requirement for gravityfeed of foam concentrate to the foampump through the strainer and avoid airtraps in the hoses. Also, clearance must beprovided to allow removal of the bowlassembly for cleaning the stainless steelmesh, to make hose connections to thestrainer and for operation of the servicevalve.

If panel mounted FS series strainers areinstalled mount the strainer in the foamconcentrate hose that suppliesconcentrate to the ADT, MDT ΙΙ or MST. TheFS series strainer may also be mounted inthe outlet hose of the MDT ΙΙ or MST. Whendetermining strainer location on theoperator panel keep in mind therequirement for gravity feed of foamconcentrate to the foam pump through thestrainer and avoid air traps in the hoses.Clearance must be provided behind thepanel to allow for hose connections to thestrainer. The installer must provide a strainerservice isolation valve in the foamconcentrate hose to prevent spillage duringservice. An MST or MDT ΙΙ can serve thispurpose also.

CONTROL UNIT and INSTRUCTION/SYSTEMDIAGRAM PLACARD: Determine a locationon the operator panel of the apparatus forthe control unit and instruction/systemdiagram placard. These components mustbe located at the main pump operatorposition in close proximity to each other.Consideration must be given for routing thecontrol cable from the control unit to thedistribution box on the foam pump andmotor assembly. If necessary, order longeror shorter cable assemblies to suit thelocation demands.

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INSTALLER SUPPLIED COMPONENTRECOMMENDATIONS

Due to the many differences in apparatusconfiguration and apparatus designrequirements the Hale FoamLogix systeminstaller must supply components such asmounting brackets, piping, hoses, fittingsand some electrical wiring. The followingguidelines are recommendations forselection of these additional componentsfor a complete system installation. Therecommendations made reflect thosematerials and components that have beentested extensively with Hale FoamLogixsystems and provide proven reliableperformance.

FOAM CONCENTRATE SUCTION HOSEThe system installer must supply fittings andhoses from the foam tank to the inlet of thefoam pump. All components selected willtransfer foam concentrate therefore theymust be compatible with the foamconcentrates being used in the system.Hoses for Class A foam concentrates musthave minimum ¾ inch (19 mm) insidediameter. Hoses for Class B foamconcentrates must have minimum 1 inch(25 mm) inside diameter due to higherviscosity of the concentrates. Certain typesof Class B AFFF-ARC or ATC concentrateswill require a 1-1/4 or 1-1/2 inch ID foamconcentrate supply line.

Hoses for the foam concentrate suctionthat WILL NOT be subjected to high pressuresuch as flushing water and foamconcentrate discharge must have a ratingof 23 in (584.2 mm) Hg vacuum and 50 PSI(3 BAR) pressure or greater. These hosesinclude the hose from the foam tank outletto strainer inlet; strainer outlet to foampump, ADT, MDT ΙΙ or MST inlet.

NFPA requires that foam concentratesuction hose be clear to observe foam

concentrate flow during foam pumpoperation.

RECOMMENDED COMPONENTS:Hose: PVC, Kuriyama Kuri-Tec K7130

seriesFittings: Hose Barb Type; Brass, Stainless

Steel or Nylon

When foam concentrate suction hose willbe subject to flushing water pressure it mustbe rated for 23 in (584.2 mm) Hg vacuumand the maximum discharge pressure of thefire pump [500 PSI (34 BAR) minimum].These hoses include the hose from theoutlet of the MDT ΙΙ or MST to the foampump inlet.

RECOMMENDED COMPONENTS:Hose: Aeroquip 2580 Series or Equivalent

Reinforced Hydraulic Hose.Fittings: Brass or Stainless Steel Hose End

Crimp or Reusable Type (Aeroquip412 Series or Equivalent)

A foam tank shut-off valve and drain valveshould be provided in the foam tank suctionhose to allow strainer service, tank drainageand easier priming. These components aresubject to the same material characteristicsand pressure ratings as stated above.When the In-line strainer/valve assemblyoption is installed the shut-off valve isincluded as an integral part of the assemblyand a separate valve is not required.

FOAM CONCENTRATE DISCHARGE HOSEThe system installer must supply fittings andhoses from the foam pump injectconnection to the check valve/injectorfitting inlet. All components selected willtransfer foam concentrate therefore theymust be compatible with the foamconcentrates being used in the system.

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The foam pump discharge port and checkvalve injector fitting connection port have½ inch NPT threads. Hoses and fittings of ½inch (13 mm) minimum inside diameterrated at 500 PSI (34 BAR) working pressure ormaximum discharge pressure of the firepump must be used. Fittings and hosesmust be compatible with all foam agents tobe used.

RECOMMENDED COMPONENTS:Hose: Aeroquip 2580-10 or Equivalent

Reinforced Hydraulic Hose.Fittings: Brass or Stainless Steel Hose End

Crimp or Reusable Type (Aeroquip412-9-10 or Equivalent)

Although air brake tubing has been used forfoam concentrate discharge hose, it is notas flexible as the hydraulic hose and readilykinks during installation. Additionally, the airbrake tubing may not meet NFPA 500 PSI(34 BAR) test requirements.

FOAM CONCENTRATE BYPASS HOSEThe foam concentrate bypass hoseconnection has ½ inch NPT threads. Hosesand fittings of ½ inch (13 mm) minimuminside diameter should be used as bypasshose. Since the bypass hose is used forcalibration and draining the system it willnot see high operating pressures, therefore,a hose with a lower pressure rating than theinject hose can be used. Fittings and hosesused must be compatible with all foamagents expected to be used. Use fittingsmade of brass or 300 series stainless steelcompatible with all foam concentrates.

RECOMMENDED COMPONENTS:Hose: Low Pressure Hydraulic Hose or Air

Brake TubingFittings: Brass or Stainless Steel

The foam concentrate bypass hose shouldbe long enough to extend past theapparatus running board making foampump setup and calibration simpler.

CHECK VALVES

Check valves must be installed onapparatus with foam systems to preventcontamination of the foam concentratewith water and contamination of the freshwater tank with foam. (Refer to figures 1-1through 1-5) When a Hale FoamLogix foaminjection system and related componentsare properly installed the required checkvalves are integral parts of the componentparts.

NFPA standards require a check valve inthe foam concentrate injection line at theinjection point. The Hale P/N 038-1790-00-0Integral Check Valve/Injector fitting, astandard component included with theHale FoamLogix system, meets theserequirements and threads directly into thefoam injection port on Hale manifolds.

Check valves must be installed in all waterpiping locations where foam concentratecould drain back into pumps or othercomponents of the fire apparatus. As aminimum one check valve must be installedwhere the water piping that will supplyfoam solution connects to the fire pumpdischarge. To more effectively keep foamcontamination out of the fire pump andwater tank double check valves should beused. Separate two check valves by atleast 8 inches (203 mm) of piping to form adead zone between the check valves.Individual drain lines should be used oneach check valve. The waterway checkvalves must be rated for 500 PSIG (34 BAR)working pressure.

Hale 3 inch "115" flange type check valves(Hale P/N 038-1570-00-0) can be used formost installations on pumps with "115" styleflanges. The Hale "115" flange type checkvalve has a 4-3/8 inch bolt circle that fitsstandard Hale "115" flanges as well as 4-3/8

inch bolt circle discharge flanges on otherpumps. These check valves are rated forpressures up to 500 PSI (34 BAR) and flowsup to 750 GPM (2839 LPM). Use 2-½ or 3inch NPT threaded "115" flanges formounting these check valves in piping runs.

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Some installations may require higher flowsand larger diameter piping. Use a Hale 4inch 2433 flange type check valve (HaleP/N 038-1570-04-0) for these installations.This check valve has an 8 bolt, 5-¾ inch boltcircle and will fit pump discharge openingsand flanges that have this configuration.The Hale 2433 check valve has a pressurerating of 500 PSI (34 BAR) and a flow ratingof 1250 GPM (4731 LPM). The Hale 2433style flange (Hale P/N 115-0040-00-0) has an8 bolt, 5-¾ inch bolt circle and 4 inch NPTthreads for in-line mounting of the 4 inchcheck valve.

FLUSHING WATER HOSEFlush water connections for the Hale ADT,Hale MDT ΙΙ or Hale MST must be madeusing ½ inch inside diameter tubing andappropriate fittings. The tubing and fittingsused must be capable of withstanding themaximum fire pump discharge pressure (500PSI (34 BAR) minimum) and should becompatible with foam concentrates beingused in the system.

When the Hale ADT, Hale MDT ΙΙ or Hale MSTis installed a check valve is providedintegral to the flushing water lineconnection to provide protection againstcontamination of the water system withfoam concentrate.

Hale recommends the use of one of theabove selector options to provide foamsystem flushing capabilities, but if the HaleFoamLogix system is ordered with the "notank" option the system installer mustprovide proper hose, shutoff valve, checkvalves and connections for flushing waterfor the system to be NFPA compliant.Additionally, when the Hale FoamLogix isinstalled without a Hale provided selectorsome operating and system protectionfeatures will not be available.

FOAM DISCHARGE DRAINSDrains must be provided from foamcapable discharge piping components to

prevent freezing in cold weather. Whendesigning the drain system care must betaken to prevent contamination of thewater system with foam and the foamconcentrate with water. Some multipledrain systems that allow individual drainlines to communicate also allow foam tobypass the installed check valves causingcontamination of fire pump and the wateror foam concentrate storage tanks.

Hale has an optional 6 port drain valve,Model MMD6 (Hale P/N 104961) thatprovides individual drains with a singlecontrol to use for applications where asingle point for multiple drains is required. Ifa Hale MMD6 drain valve is not used thenindividual drain lines and valves for foamcapable discharge piping arerecommended.

ELECTRICAL REQUIREMENTSThe system installer must provide the primarypower wire and a ground strap for the HaleFoamLogix system.

Primary power must be supplied from themain apparatus battery to the distributionbox on the foam pump and motorassembly. The Hale FoamLogix Model 5.0and Model 3.3 each require minimum 60AMP electrical service.

Primary electrical power must be supplieddirectly from the battery or the batterymaster disconnect switch or solenoids to theHale FoamLogix. Other electricalcomponents must not be supplied from thiswire. DO NOT connect the primer and HaleFoamLogix to the same power wire.

The toggle switch on the Hale FoamLogixdistribution box should be left in the ONposition at all times. So the Hale FoamLogixsystem is ready for immediate operationwhen the operator places the apparatus inpump mode, and to prevent battery powerdrain when the apparatus is not running,the primary power connection must bemade so power is supplied to the Hale

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FoamLogix when the main apparatuselectrical system is energized and the pumpis in gear. Use of a solenoid with a 200 AMPpeak, 100 AMP continuous rating isrecommended. Figure 2-1 shows therecommended wiring of this relay.

With Hale FoamLogix Model 5.0 or Model3.3, cable lengths up to 6 feet (1.8 meters)require minimum 4 AWG type SGX (SAEJ1127) battery cable. Use solder lugs oncable ends with a 5/16 inch (8 mm)diameter hole. Refer to the following tablefor the recommended battery cable size.When planning cable runs make sure theprimary wires are routed by the shortestmost direct route.

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A braided flat ground strap connected tothe apparatus chassis is recommended forthe ground connection to limit the RFI/EMIinterference encountered with radios,computers or other sensitive electronic

equipment. The ground strap should be aminimum of 1-¼ inches (32 mm) wide andbe no longer than 18 inches (457 mm). Theground strap must have soldered flat lugends with 5/16 inch (8 mm) diameter holes.If the ground strap length exceeds 18inches (457 mm), a wider ground strapshould be used or use a double thickness of1-¼ inches (32 mm) wide ground strap.

When making the ground strap connectionmake sure the connection is made to thechassis. Use minimum 5/16 inch (8 mm)diameter bolt or mounting stud for thisconnection.

Make sure the ground is attached directlyto the chassis frame and not to theapparatus body work. Before makingground connection remove all paint,grease and coatings from the connectionarea. After making connection seal againstcorrosion. When a flat ground strap is notavailable use a battery cable one sizelarger than the power cable used.

NOTE: When an inline current shuntammeter is installed on the apparatus it isnecessary to install a power filter kit (Hale P/N 546-1870-00-0) on the Hale FoamLogixfoam pump.

FOAM CONCENTRATE TANK(s)Foam concentrate tank(s) must be suppliedto suit the capacity required for theapparatus application. The tank(s) mustmeet NFPA minimum standards for theirdesign capacity, including filler size, vaporpressure venting, baffling and drainfacilities. The following table listsrecommended foam tank capacities forthe different Hale FoamLogix models basedon NFPA requirements for flammable liquid(Class B) fire suppression.

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Figure 2-1. Recommended Relay WiringSchematic

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FOAM PUMP MOUNTING

Position the foam pump and motorassembly in the desired location on theapparatus. When installing the foam pumpand motor assembly, the assembly shouldbe kept in a horizontal position with thebase plate on the bottom (see figure 2-2).Although the system is sealed and designedto be resistant to the harsh environment offire fighting apparatus, a compartment witheasy operator access is the recommendedinstallation location.

The base plate of the foam pump andmotor assembly must be anchored to asurface or structure that is rigid and ofadequate strength to withstand thevibration and stresses of apparatusoperation. Figures 2-3 and 2-4 provide themounting envelope dimensions for the HaleFoamLogix foam pump and motorassembly.

Position the foam pump so the ON/OFFswitch and bypass valve are easilyaccessible. When the Hale FoamLogixsystem is ordered without the ADT option, aseparate bypass valve is included that maybe removed from the foam pump andmounted on a truck panel for easieraccess. When the Hale FoamLogix system isordered with the ADT option, the operatingknob can be removed from the bypassvalve actuator and an extension rod canbe installed to permit remote operation. Ineither instance the foam pump and motorassembly must be located to permit properoperation of the bypass valve.

Make sure the foam concentrate hoses canbe properly routed to the inlet and outlet onthe foam pump. Foam concentrate mustgravity feed to the foam pump inlet fromthe foam tank(s). The foam pump must bemounted in an area to avoid excessiveengine exhaust system or accessory heatbuildup.

CORRECT

INCORRECT

INCORRECTFigure 2-2. Hale FoamLogix Installation

The base of the foam pump and motorassembly has predrilled mounting holes.These holes will accept 5/16 inch (8 mm)diameter bolts and the apparatus mountinglocation needs to be drilled accordingly.The base plate can be used as a templateto mark mounting hole location or amounting hole layout drawing is providedas figure 2-5.

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Figure 2-3. Hale FoamLogix Installation Envelope Dimensions

¾ INCH NPT SUCTIONHOSE CONNECTION

½ INCH NPT INJECTHOSE CONNECTION

½ INCH NPT BYPASS HOSECONNECTION

6.02 IN.(153 MM)

2.58 IN.(66 MM)

MODEL 5.0: 22.00 IN. (559 MM)MODEL 3.3: 21.75 IN. (552 MM)MODEL 5.0: 19.07 IN. (484 MM)MODEL 3.3: 18.82 IN. (478 MM)

9.43 IN.(240 MM)

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Figure 2-5. Hale FoamLogix Foam Pump and Motor Assembly Base Plate Dimensionsand Mounting Hole Locations

14.06 IN.(357 MM)

4.81 IN.(122 MM)

0.38 IN. (10 MM)DIA. THRU HOLE

(4 PLACES)

6.62 IN.(168 MM)

15.56 IN.(395 MM)

0.75 IN.(19 MM)

0.81 IN.(21 MM)

Figure 2-4. Hale FoamLogix Installation Envelope Dimensions with Optional ADT


6.02 IN.(153 MM)

3.02 IN.(77 MM)

0.87 IN. (22 MM)TO CENTER OF FLUSH

WATER INLET CONNECTION

FLUSH WATER CONNECTION½ INCH NPT

TANK B CONNECTION1 INCH I.D. HOSE

BYPASS HANDLE: BYPASS POSITION

BYPASS HANDLE: INJECT POSITION

INJECT PORT: ½ INCH NPT

BYPASS PORT: ½ INCH NPT

TANK A CONNECTION¾ INCH I.D. HOSE

4.76 IN.(121 MM)

8.95 IN.(227 MM)

6.20 IN.(157 MM)

3.70 IN.(94 MM)

MODEL 5.0: 25.37 IN. (644 MM)MODEL 3.3: 25.12 IN. (638 MM)MODEL 5.0: 24.74 IN. (628 MM)MODEL 3.3: 24.94 IN. (622 MM)MODEL 5.0: 23.70 IN. (602 MM)MODEL 3.3: 23.45 IN. (596 MM)



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WATER AND FOAM SOLUTIONPLUMBINGWhen making water and foam solutionpiping runs use the best industry practices toinstall this piping. When making threadedpipe connections use a suitable pipesealing compound at all joints.

OPTIONAL HALE PIPING COMPONENTSHale piping components such as 3 inch and4 inch wafer type check valves, 115 and2433 series flanges, mini manifold, etc. cansimplify installation of water and foamsolution discharge piping. The arrangementshown in figure 2-6 provides accurate

Hale FoamLogix System plumbing diagrams are located at the end of this manual section.The diagrams provide recommended guidelines for the installation of system componentsthat handle water, foam concentrate and foam solution. The sequence in which theplumbing installation is completed depends on the individual installation.

PLUMBING COMPONENT INSTALLATION

proportioning across a wide range for up tofour discharges from the mini manifold. Thedual check valve arrangement helps toensure that no foam concentrate willcontaminate the pump water. The Halemini manifold provides a 1 inch NPT tap forinstallation of the check valve/injectorfitting. The Hale mini manifold and elbowcomponents use 4-3/8 inch diameter boltcircles and minimize fabrication and pipework. After installation of the plumbing iscomplete make sure all pipes, hoses andtubes are supported using the best industrypractices.

HALE HPF 25FLOWSENSOR HALE MINI MANIFOLD

PROVIDES FOUR SEPARATEDISCHARGE OUTLETS.HALE "115" FLANGES AREAVAILABLE IN 1-¼ TO 3INCH FNPT SIZES.

MINIMUM LENGTH OF NIPPLE FOR2-½ INCH PIPE AS SHOWN IS 12-½INCHES (318 MM).

HALE 2H-98H ELBOW("115" Flange x 2-½ INCH FNPT)

HALE 115 WAFERTYPE CHECK

VALVEHALE 115

WAFER TYPECHECK VALVE

HALE 115 2-½INCH NPT FLANGE

SUPPORT BRACKET FORHALE MINI MANIFOLD(MANUFACTURED BYSYSTEM INSTALLER)

Figure 2-6. Typical Midship Pump Installation

HALE MIDSHIP FIRE PUMP(Shown with optional machining that provides 2 additional

Hale 115 flanged openings on top of the pump body)

CHECK VALVEINJECTOR FITTING

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consider the minimum and maximum flowrequirements during operation. Refer to theflowsensor selection chart in Section Ι of thismanual for proper pipe size for flow rangedesired.

The flowsensor is installed in the pipingbefore the foam concentrate injectionpoint.

Some applications may require flowsensoraccuracy that is not within the rangespecified for the discharge piping. This istrue in applications where the foam systemneeds to supply a 3 inch deck gun as wellas a 1 inch booster line. Since the flowthrough the deck gun will exceed thecapacity of the foam pump, pipe size forflowsensor mounting should be selected toprovide accuracy at the lower flows.Mounting the flowsensor in a short section ofpipe one pipe size smaller (4 inch to 3 inch,3 inch to 2-½ inch, 2-½ inch to 2 inch or 2inch to 1-½ inch) provides better accuracyat the lower flows. Refer to the flowsensorselection chart in Section Ι of this manual forpipe size. Selection of the next smaller pipepermits reducing the straight pipe run therequired distance prior to the flowsensorpaddlewheel then increasing the pipe size

Figure 2-7 shows a suggested installationarrangement using Hale 4 inch checkvalves, Hale 2433 flanges and 4 inch pipe.

WATERWAY CHECK VALVESCheck valves in the waterway, rated at 500PSI (34 BAR), are required to keep foamsolution out of the main pump and allowpump priming without drawing foam intothe piping. Using double check valves,separated by at least 8 inches (203 mm) ofpipe before the foam injection point, helpsensure that pump and tank water remainuncontaminated.

FLOWSENSORHale FoamLogix flowsensor is speciallydesigned to make inspection andmaintenance of the flow sensor easy. Theflowsensor paddlewheel is installed on asaddle clamp or weld fitting on the foamcapable discharge piping of theapparatus. In horizontal piping runs, theflowsensor should be mounted as close toupright as possible within the range shownin figure 2-8. DO NOT let the flowsensorsrotate more than 85o in either direction forproper operation.

When selecting flowsensor it is important to

Figure 2-7. Typical 4 Inch Check Valve Installation on Midship Pump

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on the flowsensor outlet. In the short lengthof reduced pipe pressure loss will beminimal and there will be minimal pressureloss through elbows and fittings. Figure 2-9shows a typical reduced piping runinstallation.

Excessive turbulence in the flowsensor mayproduce unstable and inaccurate flowreadings. The length of straight pipe prior tothe flowsensor must be sufficient to reducethe turbulence in the pipe. The followinginstallation guidelines will help attain thebest readings, and maintain the accuracyof the Hale FoamLogix system.

a. A minimum 6 times the pipe diameterof straight run pipe without any fittings isnecessary prior to the flowsensorpaddlewheel (see figure 2-10). Minimumrequired straight pipe run:

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b. The downstream piping length is notas critical but there should be a shortlength of straight pipe with no fittings orvalves immediately after the flowsensorpaddlewheel.

c. Do not mount a flowsensor directlyafter an elbow or valve. Valves createsevere turbulence when they are“gated”.

SADDLE CLAMP INSTALLATIONInstallation of the Paddlewheel Flowsensorusing a saddle clamp requires a 1.385/1.390inch bored hole in the pipe. A minimum ofsix times the pipe diameter of straight runpipe without any fittings is necessary prior tothe position of the hole.

Figure 2-9. Typical Reduced Flowsensor Piping Arrangement

Figure 2-8. Flowsensor Tee Position Rangein Horizontal Piping Runs

HALE 2H98 ELBOW2-½ INCH NPT

OUTLET

2-½ INCH X 2 INCHNPT REDUCER

2-½ INCHDIAMETER PIPE

2-½ INCH NPTCLOSE NIPPLE

2 INCH DIAMETERPIPE NIPPLE

MINIMUM 10 INCHES LONG2 INCH DIAMETER PIPE

NIPPLE

2-½ INCH X 2 INCHNPT REDUCER

HALE 3 INCHCHECK VALVE

MIDSHIP PUMPCONNECTION

HALE HPF 20FLOWSENSOR

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For proper installation, the flowsensorrequires the use of a spacer and eightstainless steel internal hex head screws.Four 6 – 32 x ½ inch screws attach thespacer to the saddle clamp mount, andfour 6 – 32 x ¾ inch screws with lockwashersattach the paddlewheel to the spacer.

Align the spacer to the saddle clampmount by arranging the indexing pin of thesaddle clamp with the indexing hole of thespacer. Use four ½ inch machine screwswithout lockwashers to secure the twopieces. Torque to 8.5 inch pounds.

Align the paddlewheel indexing pin to theindexing hole in the spacer, secure usingfour ¾ inch screws and lockwashers.Torque to 7.5 inch pounds.

Apply a small amount of grease to thesaddle clamp gasket before the finalinstallation of the assembly onto the pipe.Tighten the saddle clamp onto the pipefirmly.

The paddlewheel should be installed asclose to upright as possible within the rangeshown in figure 2-8. Do not let theflowsensor rotate more than 85 degrees in

Figure 2-10. Flowsensor Placement

WATERINLET

WATERINLET

VALVE ORFITTING AFTERFLOWSENSOR

VALVE OR FITTING BEFOREFLOWSENSOR WITH LESS THAN 5X

THE PIPE DIAMETER BETWEEN

AT LEAST 5X THE PIPEDIAMETER BETWEEN

VALVE OR FITTING ANDFLOWSENSOR

CORRECT

INCORRECT

either direction for proper operation.

FOAM PUMP FLUSH SYSTEMWhen dual foam tanks are installed on theapparatus, flushing water must be providedto flush the system of foam concentrateafter use of some foam concentrate typesto prevent possible reactions. The Hale ADTand Hale MDT �� each have provisions forconnecting flushing water to the foamconcentrate injection system.

If a single foam concentrate tank system isinstalled on the apparatus the Hale MSTprovides a selector valve and gives thesystem flush capabilities for NFPAcompliance. A fitting provided on the HaleMST makes connection of flushing watersimple.

When the Hale FoamLogix is installed withthe "no tank" option the system installer mustprovide flushing water supply to complywith NFPA standards.

Flushing water hose should have a minimumof ½ inch (12 mm) inside diameter and becapable of withstanding the maximum firepump discharge pressure, 500 PSI (34 BAR)minimum. The flush water supply should beprovided from one of the pressure taps onthe discharge of the fire pump. It isrecommended that a check valve beinstalled at the pressure tap to preventcontamination. Flush water threadconnections on the ADT are ½ inch NPT andon the Hale MDT ΙΙ and Hale MST they are ¼inch NPT. The system installer must provideproper fittings for these connections.

FOAM CONCENTRATE PLUMBINGFoam concentrate plumbing consists of thefoam concentrate suction hose, foamstrainer, foam concentrate discharge hoseand check valve/injector fitting.

CAUTION: Make sure the foam tank andfoam concentrate suction hoses areclean before making final connection tofoam pump. Flush tank and hoses prior

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to making connections.

NOTE: Foam concentrate gravity fed.

FOAM STRAINERIN-LINE STRAINER/VALVE ASSEMBLY

CAUTION: The in-line strainer/valveassembly is a low pressure device andWILL NOT withstand flushing waterpressure. When installing the in-linestrainer in systems equipped with HaleMDT ΙΙ or Hale MST make sure the in-linestrainer/valve assembly is in the hose onthe inlet side of the valve. If the strainerwill be subject to flushing water pressure,use Hale FS series strainers.

The in-line strainer/valve assembly has 1-1/4inch NPT female threaded ports. Fittings aresupplied for connection of ¾ inch (19 mm),

1 inch (25 mm) or 1-1/4 inch (32 mm) insidediameter hose depending on the viscosityof foam concentrates used. (See figure 2-12) Generally ¾ inch inside diameter hosewill be used for Class A foam and 1 inchinside diameter hose will be used for Class Bfoams. For high viscosity Class B foamconcentrates it may be necessary to use 1-1/4 or 1-1/2 inside diameter hose. Abracket is included with the in-line strainer/valve assembly to permit installation on theapparatus.

The hose from the foam tank(s) to thestrainer should have adequate wall stiffnessto withstand the vacuum of the foam pumpwhile it is operating [23 inches (584 mm) Hgand 50 PSI (3 BAR)] (Kuriyama, Kuri-tec K-7130 series or equal).

The following procedures are provided forinstallation of the in-line strainer/valveassembly:

1. Choose a location on the apparatusthat allows gravity feed from the foamtank to the strainer inlet and from thestrainer outlet to the foam pump suctionconnection.

NOTE: When selecting the strainerlocation make sure there is sufficientspace below the strainer for removal ofthe strainer basket and screen forcleaning. A minimum of 5 inches (127mm) is required for this purpose. Alsomake sure there is at least 2 inches (51mm) above the strainer assembly topermit operation of the service valve.(Refer to figure 2-12)

2. Refer to the diagram in figure 2-13 andmark 4 holes for mounting the foamstrainer bracket. The holes must bedrilled to accommodate ¼-20 UNCscrews. The holes can either be tapped(#7 drill for ¼-20 UNC tap) or drill largeenough to use screws, nuts and washers(9/32 inch (7 mm) diameter) to secure

Figure 2-11. Flowsensor Sensor Service

WATER FLOW DIRECTION

SADDLE CLAMP

O-RINGS

SENSOR

ΙΙ -17

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the bracket to the apparatus. Securethe bracket and strainer/valve assemblyto the apparatus.

3. Select the appropriate fittings from thebag attached to the strainer assembly.Two of each fitting are included with thestrainer assembly.

For Class A foam concentrate use thesupplied 1-1/4 inch NPT x ¾ inch hosefittings in each end of the strainer/valveassembly.

For most Class B foam concentrates usethe 1-1/4 inch NPT x 1 inch hose fittings.

When using higher viscosity Class B ATCconcentrates use the 1-1/4 inch NPT x 1-1/4 inch hose fittings

Before assembly coat all fitting threadswith Permatex #80724 (or equal) plasticpipe thread sealant. Install the fittingsinto the strainer/valve assembly endsand tighten securely.

4. Install the clear plastic hose from thefoam tank outlet to the inlet of thestrainer/valve assembly. The inlet of thestrainer/valve assembly is on the valve

end. Wetting the ends of the hose andfittings will make the installation on thehose fittings easier.

CAUTION: Make sure the foam tank andfoam concentrate suction hoses areclean before making final connection tofoam pump. If necessary flush tank andhoses prior to making connection.

5. Install the clear plastic hose from the in-line strainer/valve assembly outlet to the

Figure 2-13. In-Line Strainer MountingBracket Hole Layout Dimensions

STRAINER BRACKET OUTLINESHOWN FOR CLARITY

3-1/8 IN.(79 MM)

2-21/32 IN.(67 MM)

4 HOLES (#7 DRILLIF TAPPED ¼-20UNC or 9/32 IN (7MM) DIAMETER

Figure 2-12. In-Line Strainer/Valve Installation

1-1/4 INCH NPT X 3/4 INCHHOSE BARB

(Use on each end for ClassA foam concentrates)

1-1/4 INCH NPT X 1-1/4INCH HOSE BARB

(Use on each end for ClassB foam concentrates)

2 INCHES (51 mm) MINIMUMCLEARANCE ABOVE FOR

VALVE OPERATION

STRAINER SERVICEVALVE

(Shown in openposition. Rotate 90o

clockwise to close)

STRAINERMOUNTINGBRACKET

5 INCHES (127 mm) MINIMUMCLEARANCE BELOW FORELEMENT MAINTENANCE

FOAMCONCENTRATE

INLET

FOAMCONCENTRATE

OUTLET

1-1/4 INCH NPT X 1 INCHHOSE BARB

(Use on each end forClass B foamconcentrates)

ΙΙ -18

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Figure 2-15. FS Series Strainer Mounting Dimensions

4.28 IN.(109 MM)

3.00 IN.(76 MM)0.34 IN. (9 MM)

DIA. THRU HOLE(4 PLACES)

1.00 IN.(25 MM)

1.00 IN.(25 MM)

1.50 IN.(38 MM)

0.88 IN.(22 MM) 1.13 IN.

(29 MM)

3.00 IN.(76 MM)

1.50 IN.(38 MM)

4.75 IN.(121 MM)

2.38 IN.(60 MM)

3.38 IN. (86 MM)DIA. HOLE

7.09 IN.(180 MM)

1 INCH NPTTHREADED

OUTLET

1 INCHNPT

THREADEDINLET

2-½ INCHNST CAP

¾ INCH NPTTHREADED

OUTLET

¾ INCH NPTTHREADED

INLET

1-½ INCHNST CAP

7.34 IN.(186 MM)

0.28 IN. (7 MM)DIA. THRU HOLE

(4 PLACES)

2.13 IN. (54 MM)DIA. HOLE

2.14 IN.(54 MM)

4.28 IN.(109 MM)

TYP.

OPERATORPANEL

OPERATORPANEL

FS15 STRAINER FS25 STRAINER

inlet of the Hale MDT ΙΙ , Hale MST orfoam concentrate pump or correctfitting on Hale ADT.

FS SERIES STRAINERWhen a pressurized water flush is providedto the strainer from one of the dischargesthe use of Hale FS series strainers is required.The plumbing exposed to the flush waterpressure must be rated at or above theoperating pressure of all other dischargeplumbing components. [500 PSI (34 BAR)minimum]

The following procedures are provided forinstallation of FS series strainers:

1. Choose a location on the apparatusthat allows gravity feed from the foamtank to the strainer inlet and from thestrainer outlet to the foam pump suctionconnection.

NOTE: When selecting the strainerlocation make sure there is sufficientspace behind the pump panel to permitattaching hoses and fittings. Make surethe inlet connection port is oriented asshown in figure 2-14 when installing theFS series strainer.

2. Remove the strainer cap, mountingscrews and nameplate from the strainerassembly.

3. Using the nameplate as a guide, or referto the diagrams in figure 2-15, mark

Figure 2-14. FS Series Strainer OrientationLOOKING FROM BACK OF STRAINER

ΙΙ -19

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holes for mounting the foam strainer.The holes for the FS15 strainer mountingscrews are 9/32 inch (7 mm) and theholes for FS25 strainer screws are 11/32inch (9 mm) diameter. Additionally ahole of sufficient size for the cap threadsto clear the panel is required. [FS15strainer 2.13 inches (54 mm) and FS25strainer 3.38 inches (86 mm)]

4. Select appropriate fittings forattachment of the hoses to the strainer.The fittings and hoses chosen must becapable of withstanding the vacuumgenerated by the foam pump [23inches (584 mm) Hg] and the maximumflushing water pressure [500 PSI (34BAR)].

When using an FS15 strainer use ¾ inchNPT x ¾ inch hose fittings.

When using an FS25 strainer use 1 inchNPT x 1 inch hose fittings.

Before assembly coat all fitting threadswith a suitable thread sealant (Do notuse Teflon tape). Install the fittings intothe strainer and tighten securely.

5. Make sure the strainer is oriented asshown in figure 2-14 and secure thestrainer body and nameplate to theapparatus with the screws provided.Install the cap on the strainer.

6. Install the hose from the foam tankoutlet to the inlet of the strainer. Theinlet of the strainer is closer to theoperator panel and is oriented as shownin figure 2-14. Wetting the ends of thehose and fittings will help easeinstallation on the hose fittings.

CAUTION: Make sure the foam tank andfoam concentrate suction hoses areclean before making final connection tofoam pump. Flush tank and hoses priorto making connection.

7. Install the hose from the strainer outlet tothe inlet of the Hale FoamLogix foampump or selector valve.

CHECK VALVE/INJECTOR FITTINGThe Hale check valve/injector fittingsupplied with the Hale FoamLogix systemmeets NFPA requirements for a non-returndevice in the foam injection system toprevent back flow of water into the foamconcentrate tank. When properly installedthe brass and stainless steel constructioncheck valve/injector fitting ensures foamconcentrate is injected into the center ofthe water flow for better mixing.

NOTE: Always position the check valve/injector fitting at a horizontal or higherangle to allow water to drain away fromthe fitting (see figure 2-16). This will avoidsediment deposits or the formation of anice plug.

The check valve/injector fitting MUST bemounted in a location that is common to alldischarges which require foam concentrate(see figure 2-18). The Hale FoamLogixsystem does not permit a separate injectionpoint for each foam capable discharge.

The check valve/injector fitting has 1 inchNPT threads on the outside to fit into the 1

CORRECT

INCORRECT

CHECK VALVE/INJECTOR FITTINGBELOW HORIZONTAL PLANE

Figure 2-16. Check Valve/Injector FittingPosition

CHECK VALVE/INJECTOR FITTINGABOVE HORIZONTAL PLANE

ΙΙ -20

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Figure 2-18. Injection and Bypass Hose Connections

FOAMCONCENTRATE

INLET¾ INCH NPT

FOAMPUMP

BYPASSVALVE

INJECT PORT½ INCH NPT

BYPASS PORT½ INCH NPT

FOAM CONCENTRATEINLET CONNECTION

FOAM PUMP NOTSHOWN FOR

CLARITY

BYPASS VALVEHANDLE

INJECT PORT½ INCH NPT

BYPASS PORT½ INCH NPT

HALE FOAMLOGIX WITH NO TANK, MSTOR MDT ΙΙ OPTION HALE FOAMLOGIX WITH ADT OPTION

FLUSHING WATERPORT ½ INCH NPT

inch NPT threaded connection on the Halemini manifold, a pipe tee or a 1 inch NPTweld fitting installed in the discharge pipingof the fire pump (see figure 2-17). The inletconnection of the check valve/injectorfitting has ½ inch NPT female threads.

FOAM CONCENTRATE INJECTION HOSEConnect hose from the foam pump injectport (see figure 2-18) to the inlet of thecheck valve injector fitting. The hose andfittings from the INJECT port to the checkvalve injector fitting should have minimum½ inch (13 mm) inside diameter and be

rated at 500 PSI (34 BAR) working pressure(Aeroquip 2580-10 or equal).

BYPASS HOSE CONNECTIONA bypass port is provided on the dischargeside of the Hale ADT or a 1/4 turn bypassvalve is mounted on the discharge of thefoam pump when the ADT option is notinstalled. The bypass handle shall beaccessible by the pump operator duringnormal operations.

The bypass valve is a 3-way directionalvalve that selects where the output of thefoam pump will go. Determine which port isthe INJECT port (see figure 2-18) and whichport is the BYPASS port. The INJECT port isidentified on the bypass valve placard.Look at the ports as you move the handle,the flow should go from the center port toeach of the other ports. The bypass port onthe ADT is identified by a label above theport.

Bypass hose connections are ½ inch NPTthreads. Hose fittings compatible with allfoam concentrates to be used must beprovided. The hose from the BYPASS port isplumbed to the atmosphere and should notreceive high pressures. This hose is used forcalibrating the foam pump, pumping theconcentrate into a container to empty the

Figure 2-17. Check Valve Injector FittingInstallation

CHECK VALVEINJECTOR

FITTING

1 INCH NPTTHREADS

½ INCH NPT THREADS(FOAM CONCENTRATE INLET)

HALE MANIFOLD,PIPE TEE OR

WELD BOSS ONPIPE

ΙΙ -21

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foam tank or to assist in priming of the foampump. The hose from the BYPASS port mustbe long enough to reach a containeroutside the truck. This hose must be coiledfor storage when not in use.

If the handle or placard is removed fromthe bypass valve for repairs or to facilitateremote mounting make sure they areinstalled on the valve correctly. Make surethe tang on the handle engages the caststops as shown in figure 2-9.

ADT AIR CONNECTIONSIf the ADT option is used, install theoperating switch and indicator light placardfor the ADT on the apparatus operatorpanel. A mounting cutout diagram isprovided as figure 2-20.

After mounting the placard assembly installthe air hoses from the ADT to the placardassembly. Make sure proper connectionsare made at the placard assembly as Figure 2-19. Bypass Valve Assembly

ACORN NUT

BYPASS HOSECONNECTION

INJECT HOSECONNECTION

PLACARD

CASTBOSSES

HANDLETANG

PLACARDSCREWS

HANDLE

Figure 2-20. ADT Panel Placard Panel Cutout and Hole Dimensions

0.84 IN.(21 mm)

DRILL 4 THRU HOLES7/32 IN. (6 mm) DIA.

0.63 IN.(16 mm)

0.25 IN.(6 mm)RADIUS

TYP.

3.50 IN.(89 mm)

2.75 IN.(70 mm)

1.38 IN.(35 mm)

1.63 IN.(41 mm)

1.69 IN.(43 mm)

1.25 IN.(32 mm)

PLACARD OUTLINE SHOWNFOR REFERENCE ONLY

ΙΙ -22

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indicated in figure 2-21. A color codeddecal attached to the ADT valve assemblyalong with an optional color coded air hoseharness simplifies air hose connections. Ifthe optional air hose harness is not used ¼inch inside diameter air brake tubing can

be substituted. Make sure the air braketubing selected has the proper DOTapproval. When cutting the air harness orair brake tubing to size make sure the endsare square using a tubing cutter or razorknife.

ΙΙ -23

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Figure 2-21. ADT Air Hose Connections

AIR IN(BLACK)

AIR OUT B(RED)

ELECTRICAL HARNESS

ADT PANEL PLACARD SIDE VIEW

TANK AINDICATOR

AIR OUT A(GREEN)

TANK BINDICATOR

SELECTORSWITCH

AIR OUT(BLACK)

AIR IN B(RED)

AIR IN A(GREEN)

AIR SUPPLY FROMAPPARATUS AIR SYSTEM

ADT ASSEMBLY(FOAM PUMP NOT

SHOWN FOR CLARITY)

PANELPLACARD

ASSEMBLY

¼ INCH O.D. AIRHOSE OR AIR

HARNESSASSEMBLY

TOP VIEW OF ADT ASSEMBLY

ΙΙ -24

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SYSTEM PLUMBING DIAGRAMSThe following pages contain Hale FoamLogix system plumbing diagrams for the varioussystem configurations. Due to variations in apparatus configuration and individualcomponent locations, lengths of hoses and piping is not provided. The material describedand component sizes are those which will provide optimum performance of a HaleFoamLogix system. These diagrams are intended as guidelines to assist the system installerwith selection of hoses and fittings along with the connections required.

ΙΙ -25

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BYPASSVALVE

FOAM INJECTIONHOSE ½ INCH (12 MM)

INSIDE DIAMETERRATED FOR 500 PSI

(34 BAR) WITH ½INCH NPT FITTINGS

BYPASSHOSE

WATERWAYCHECKVALVE

FOAM PUMP ANDMOTOR

ASSEMBLY


WATERWAYCHECKVALVE

CHECK VALVEINJECTOR

FITTING


FIREPUMP

FOAMTANK

FOAM TANKDRAINVALVE

FOAM SUCTION HOSE¾ INCH (19 MM) INSIDE

DIAMETER CLEARRATED AT 23 INCHES(584 mm) Hg VACUUM

and 50 PSI (3 BAR)

1 INCH NPT x ¾ INCHNPT BUSHING¾ INCH NPT x ¾ INCH

HOSE FITTING

¾ INCH NPT x ¾ INCHHOSE FITTING


DIAMETER CLEARRATED AT 23 INCHES(584 mm) Hg VACUUMand 500 PSI (34 BAR)

IMPORTANT: When Hale FoamLogix system is orderedwithout a tank option the installer must provide thefittings necessary for flushing the foam system to beNFPA compliant. These components are:Foam concentrate check valve; prevents watercontamination of foam tank and pressurization of in-line strainer/valve assembly.Tee; to connect flush water hose to foam concentratehose.Flush Water Check Valve; prevents foamcontamination of water system.Flush Water Shutoff Valve

FLUSH WATER SUPPLY HOSE 3/8

OR ½ INCH (10 or 12 MM)OUTSIDE DIAMETER RATED AT

500 PSI (34 BAR)

FOAMCONCENTRATECHECK VALVE

TEEFLUSH WATERVALVE

FLUSH WATERCHECK VALVE

Hale FoamLogix System Plumbing Diagram with Single Foam Concentrate Tank

HALEFLOWSENSOR


SADDLECLAMP

ΙΙ -26

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Hale FoamLogix System Plumbing Diagram with Single Foam Concentrate Tank, MST andIn-line Strainer/Valve Assembly

FOAMTANK

FOAM TANKDRAINVALVE

BYPASSVALVE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLY


CHECK VALVEINJECTOR

FITTING





1 INCH NPT x ¾ INCHNPT BUSHING





and 50 PSI (3 BAR)



and 50 PSI (3 BAR)

FOAM SUCTION HOSE¾ INCH (19 MM) INSIDEDIAMETER RATED FOR

23 INCHES (584 mm)Hg VACUUM and 500

PSI (34 BAR)

FLUSH WATER SUPPLY HOSE3/8 OR ½ INCH (10 or 12 MM)OUTSIDE DIAMETER RATED

AT 500 PSI (34 BAR)

MST SELECTOR¾ INCH NPTFOAM HOSE

CONNECTIONS

¼ INCH NPTFLUSH HOSECONNECTION

BYPASS HOSEAIR BRAKE TUBING ½

INCH INSIDE DIAMETER

HALEFLOWSENSOR


SADDLECLAMP

ΙΙ -27

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Hale FoamLogix System Plumbing Diagram with Single Foam Concentrate Tank, MST andFS Series Strainer

FOAMTANK

FOAM TANKDRAINVALVE

FOAM TANKSHUTOFF

VALVE

MST SELECTOR¾ INCH NPTFOAM HOSE

CONNECTIONS

BYPASSVALVE

BYPASSHOSE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLY


CHECK VALVEINJECTOR

FITTING




¾ INCH NPT x ¾ INCHHOSE FITTINGS FOR FS15

STRAINER



and 50 PSI (3 BAR)



PSI (34 BAR)


AT 500 PSI (34 BAR)

1 INCH NPT x ¾ INCH HOSEFITTINGS FOR FS25

STRAINER

¼ INCH NPTFLUSH HOSECONNECTION

HALEFLOWSENSOR


SADDLECLAMP

ΙΙ -28

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FOAMTANK B

FOAMTANK A

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

BYPASSVALVE


CHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLY


CHECK VALVEINJECTOR

FITTING

Hale FoamLogix System Plumbing Diagram with Dual Foam Concentrate Tanks, MDT ΙΙand In-line Strainer/Valve Assembly

MDT �� SELECTOR ¾INCH NPT FOAM

HOSE CONNECTIONS




FOAM SUCTION HOSE1 INCH (25 MM) INSIDE


and 50 PSI (3 BAR)



PSI (34 BAR)


AT 500 PSI (34 BAR)

¼ INCH NPTFLUSH ANDDRAIN HOSE

CONNECTIONS


1 INCH NPT x 1 INCHHOSE FITTING




and 50 PSI (3 BAR)



HALEFLOWSENSOR


SADDLECLAMP

ΙΙ -29

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CHECKVALVE

FIREPUMP


Hale FoamLogix System Plumbing Diagram with Dual Foam Concentrate Tanks, MDT ΙΙand FS Series Strainer Assembly

FOAMTANK B

FOAMTANK A

FOAM TANKSHUTOFF

VALVE FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

FOAM TANKSHUTOFF

VALVE

BYPASSVALVE

FOAM PUMP ANDMOTOR

ASSEMBLY

CHECK VALVEINJECTOR

FITTING

MDT �� SELECTOR ¾INCH NPT FOAM

HOSE CONNECTIONS






and 50 PSI (3 BAR)



PSI (34 BAR)


AT 500 PSI (34 BAR)

¼ INCH NPTFLUSH ANDDRAIN HOSE

CONNECTIONS



and 50 PSI (3 BAR)

¾ INCH NPT x ¾ INCHHOSE FITTINGS FOR FS15

STRAINER1 INCH NPT x ¾ INCH HOSE

FITTINGS FOR FS25STRAINER



HALEFLOWSENSOR


SADDLECLAMP

ΙΙ -30

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WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP


Hale FoamLogix System Plumbing Diagram with Dual Foam Concentrate Tanks, ADT andIn-line Strainer/Valve Assemblies

FOAMTANK B

FOAMTANK A

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

FOAM PUMP ANDMOTOR

ASSEMBLY

CHECK VALVEINJECTOR

FITTING






and 50 PSI (3 BAR)


AT 500 PSI (34 BAR)

½ INCH NPTFLUSH HOSECONNECTION


1 INCH NPT x 1 INCHHOSE FITTING




and 50 PSI (3 BAR)



HALEFLOWSENSOR


SADDLECLAMP

ΙΙ -31

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Hale FoamLogix System Plumbing Diagram with Dual Foam Concentrate Tanks, ADT andFS Series Strainer Assemblies

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP


FOAMTANK B

FOAMTANK A

FOAM TANKSHUTOFF

VALVE

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

FOAM TANKSHUTOFF

VALVE

FOAM PUMP ANDMOTOR

ASSEMBLY

CHECK VALVEINJECTOR

FITTING

FOAM INJECTION HOSE½ INCH (12 MM) INSIDEDIAMETER RATED FOR

500 PSI (34 BAR) WITH ½INCH NPT FITTINGS



and 50 PSI (3 BAR)


AT 500 PSI (34 BAR)½ INCH NPT

FLUSH HOSECONNECTION



and 50 PSI (3 BAR)

¾ INCH NPT x ¾INCH HOSE

FITTINGS FORFS15 STRAINER

1 INCH NPT x¾ INCH HOSEFITTINGS FOR

FS25STRAINER



HALEFLOWSENSOR


SADDLECLAMP

ΙΙ -32

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ΙΙ -33

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ELECTRICAL INSTALLATIONELECTRICAL CONNECTIONSComplete system electrical diagrams areprovided at the end of this manual section.Refer to these diagrams for proper hookupof each of the electrical components. TheHale FoamLogix system is designed to beinstalled with a minimum of electricalconnections. Complete electricallyshielded cables are provided with eachHale FoamLogix system to make theflowsensor, control unit and distribution boxconnections. The system installer mustsupply primary power wire, low tank levelsensor wire and flat braided ground straps.

ELECTRICAL INSTALLATION CAUTIONS• To prevent system damage or electrical

shock the main power supply wire will bethe last connection made to the HaleFoamLogix distribution box.

• The cables provided with each HaleFoamLogix system are shieldedassemblies. Never attempt to shorten orlengthen the cables. If necessary orderlonger or shorter cables from HaleProducts to suit the particular installation.

• The cables are indexed so they only go inthe correct receptacle and they canonly go in one way. When making cableconnections DO NOT force mismatchedconnections as damage can result inimproper system operation.

• The system can only perform when theelectrical connections are sound, somake sure each one is correct.

• Hale FoamLogix systems are designed foruse on direct current, negative groundapparatus electrical systems only.

• Do not mount radio transmitter ortransmitter cables in direct or closecontact with the Hale FoamLogix unit.

• Before connecting the cables inspect theo-ring seal in the female connector. Ifthe seal washer is missing or damaged,water can enter the connector causingcorrosion of the pins and terminalsresulting in possible system failure.

• The cables shipped with each HaleFoamLogix system are tested at thefactory with that unit. Improper handlingand forcing connections can damagethese cables which could result in othersystem damage.

• The ground strap must be a minimum of1-¼ inches (32 mm) wide and no longerthan 18 inches (457 mm). A longerground strap must be wider or a doublethickness strap must be used. Make surethe ground strap is attached to thechassis frame. Grounding to the body ISNOT acceptable.

• Always disconnect the power cable,ground straps, electrical wires and cablesfrom the control unit or other HaleFoamLogix equipment before electricarc welding at any point on theapparatus. Failure to do so will result in apower surge through the unit that couldcause irreparable damage.

• There are no user serviceable parts insideHale FoamLogix system electrical/electronic components. Opening ofthese components (distribution box orcontrol unit) will void warranty.

• When an inline current shunt ammeter isinstalled on the apparatus power filter kit(Hale P/N 546-1870-00-0) on the HaleFoamLogix foam pump.

CONTROL UNITThe control unit mounts in the operatorpanel of the apparatus. The display issecured with four #10 socket head screws in

ΙΙ -34

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the four holes in the face (See figure 2-22 formounting dimensions). The display requires7 inches (178 mm) minimum clearance fromthe back of the operator panel to allowproper connection of cables. Once thecontrol unit is mounted on the operatorpanel, attach the 14 pin AMP connector onthe flow sensor cable assembly to the backof the display. Referring to figures 2-23 and2-24 make connections to the distributionbox and flow sensor.

NOTE: Ensure that the panel where thecontrol unit is mounted has anadequate ground. For stainless steeland vinyl coated panels a ground strap½ inch (12 mm) wide must be attachedfrom one of the four screws holding thecontrol unit in place to the frame of thefire truck to ensure adequate grounding.

FOAM TANK LOW LEVEL SENSORINSTALLATIONThe foam tank low tank level sensor(s) mustbe installed and wired to monitor foamconcentrate level. Mount a low tank levelsensor in each foam tank as follows. Referto figure 2-25 for low tank level sensormounting options.

CAUTION: Foam tank low level sensorsmust be utilized to protect the HaleFoamLogix from dry running. Failure touse low level sensors with the HaleFoamLogix system will void warranty.

SIDE MOUNT LOW LEVEL SENSORINSTALLATION1. A side mount low tank level sensor isavailable to be used if the bottom of thefoam tank is not accessible. The side mountlow tank level sensor has ½ inch NPTthreads. If tank design and constructionallows, the side mount sensor can bethreaded directly into the side of the tank atthe proper height. Also the sensor can bemounted on the foam tank using a ½ x 1inch NPT bushing and a bulkhead fittingwith 1 inch FNPT threads (see figure 2-26).The center of the switch must be located atleast 1-½ to 2 inches (38 to 51 mm) from thebottom of the foam tank with the floatpositioned on top of the switch to move upand down.

NOTE: When the side mount low tanklevel sensor senses a low concentratecondition the system will operate for oneminute unless the foam concentratelevel is restored. If the foam

Figure 2-22. Control Unit Mounting Dimensions

7.00 IN. (178 MM)CLEARANCE BEHIND OPERATOR PANEL

ΙΙ -35

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concentrate level is not restored theHale FoamLogix system will shut down.When locating the side mount low tank

Figure 2-24. Control Unit Cable Connection

Figure 2-23. Distribution Box Connections

LOW TANK SENSORCONNECTION **

(WHEN SINGLE TANK OR MSTOPTION IS ORDERED A KIT

WITH THE MATING PACKARDCONNECTOR IS INCLUDED.)

PRIMARY POWER CONNECTION(60 AMPS MINIMUM) *

USE MINIMUM 4 AWG TYPE SGX (SAE J1127) BATTERY CABLEFOR CABLE LENGTH UP TO 6 FEET.

FOR CABLE LENGTH OVER 6 FEET REFER TO TABLE 2-2 FORPROPER GAUGE WIRE

.(Use Silicon Sealant to Prevent Corrosion anduse Rubber Boot Provided to Prevent Short

Circuit)

CONTROL UNITCABLE CONNECTION

(6-PIN) *

POS (+) MOTORTERMINAL

ACCESSORY CONNECTOR(Plug inserted at factory when single tank installed.)

(Connection made at factory when Hale MDT �� or Hale ADT option installed.)(Field connection required at installation when Hale MST option installed.)

* CONNECTION MADE DURING SYSTEM INSTALLATION.** CONNECTION REQUIRED WHEN SINGLE TANK OR

HALE MST INSTALLED.

NEG (-) MOTORTERMINAL

FEEDBACKSENSOR PIGTAIL

CHASSIS GROUND STRAP CONNECTION *USE 1-¼ INCH WIDE FLAT BRAIDED GROUND STRAP MAXIMUM

18 INCHES (457 mm) LONG

(Use Silicon Sealant to Prevent Corrosion)

level sensor on the foam tank sufficientfoam concentrate should be present forone minute of operation at rated flow.

FLOWSENSOR(10, 20 OR 30 FEET LONG)

CONTROL CABLETO DISTRIBUTION BOX

(6 FEET LONG)

REMOTE ACTUATIONSWITCH

(20 INCHES LONG)

CAN CONNECTION(20 INCHES LONG)

(FOR CAFSProINSTALLATIONS ONLY)

BACK OF CONTROL UNIT

14 PIN AMP CONNECTORCONNECTS TO BACK OF

FoamLogix CONTROL UNIT

DISPLAY POWER GROUNDCONNECTION

(12 INCHES LONG)RED=POWER; BLACK=GND

ΙΙ -36

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Figure 2-26. Side Mount Foam Tank LowLevel Sensor Installation

1-½ to 2 in.(38 to 51 mm)

BULKHEADFITTING

LOW TANKLEVEL SENSOR

ASSEMBLY

BOTTOM OF FOAM TANK

FLOAT POSITION(INSUFFICIENT FOAM

CONCENTRATE IN TANK)

FLOAT POSITION(SUFFICIENT FOAM

CONCENTRATE IN TANK)

2. Coat the threads of the low tank sensorwith suitable sealant and insert into tankfitting. Tighten sensor making sure the floatis on the top of the sensor.

3. After installation, check operation of theside mount low tank level sensor with apowered test light. With no foam in thetank, the light should be on. If light does notilluminate, rotate the side mount low tanklevel sensor until the test light is on.

Figure 2-25. Foam Tank Low Level SensorMounting Options

BOTTOM MOUNTLOW LEVEL

SENSOR OPTION

SIDE MOUNTLOW LEVEL

SENSOROPTION

TOP MOUNT LOWLEVEL SENSOR

OPTION

TYPICALFOAM TANK

BOTTOM MOUNT LOW LEVEL SENSORINSTALLATION1. The bottom mount foam tank low levelsensor must be mounted into the bottom ofthe foam tank. The sensor, as supplied, isthreaded into a bushing that has 1 inch NPTthreads. The sensor is designed to beinstalled from the outside of the foam tankthrough a bulkhead fitting or boss with 1inch FNPT threads. Mount the sensor in thebottom of the foam tank in an uprightposition. Use suitable sealant to preventconcentrate leakage.

NOTE: There must be sufficient spaceunder the foam tank for the low tanklevel sensor wires to be routed to thefoam pump/motor assembly. Be surenot to remove the float from the shaft onthe low tank level sensor assembly. If thefloat is installed in the reverse position,“lo A” or “lo b” will appear on thecontrol unit and the system willautomatically shut down even if there isfoam in the tank.

2. Check low tank level sensor operationwith a powered test light. With no foam inthe tank, the light should be on. If this is notthe case, remove the clip from the end ofthe sensor. Remove float and reinstall 180o

out of position. Reinstall clip.

TOP MOUNT LOW LEVEL SENSORINSTALLATIONA top mount low level sensor assembly isavailable for installations where the sides orbottom of the foam tank are not accessibleor sensor service is required without drainingthe foam tank. The sensor assembly isflange mounted in an access hole at thetop of the foam tank. The two sectiontelescoping assembly permits adjustment oflow tank level sensor position for variousfoam tank depths from 31-½ to 60 inches(800 to 1524 mm). Flange cutoutdimensions are shown in figure 2-27. Theflange gasket can also be used as atemplate to mark hole location.

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1. Using dimensions in figure 2-27, layoutand drill holes in the top of the foamtank. The center of the sensor should belocated at least 1-½ to 2 inches (38 to 51mm) from the sides of the foam tank.

NOTE: The minimum depth of foam tankfor installation of the top mount sensorwithout cutting the tube sections is 31-½inches (800 mm). If the tank depth is lessthan 31-½ inches (800 mm) cut thetubing as described in step c.

2. Determine the approximate length ofthe top mount low tank sensor extensionby measuring from the top of the foamtank at the flange opening to thebottom of the tank. When properlyinstalled the center of the sensor floatshould be 1-½ to 2 inches (38 to 51 mm)above the bottom of the foam tank.

3. Slide the flange to the top of the 5/8inch diameter tube and adjust thetelescoping section until the desiredlength is achieved as measured fromthe bottom of the flange to the bottomof the sensor. Tighten the compressionfittings on the union to lock length.

CAUTION: Use mounting hardware thatis compatible with all foamconcentrates to be used in the system.Use washers, lockwashers andcapscrews made of brass or 300 seriesstainless steel.

4. Insert sensor assembly through the1.31 inch (33 mm) hole and align thescrew holes on the flange and gasketwith the holes on the tank. Secure theassembly in place using four ¼-20 UNC x1 inch long cap screws, ¼ inch washersand ¼ inch lockwashers.

5. Make final adjustment to the sensorposition by pulling the tubing sections upthrough the flange until sensor is 1-½ to 2inches (38 to 51 mm) from the bottom ofthe tank. Tighten the 5/8 tubecompression nut on the flange.

6. Close strain relief to the 900 positionmaking sure it snaps shut. Tighten strainrelief gland nut to seal out water andcontamination.

RESIZING THE LOW LEVEL SENSOR

Some applications may require the topmounted sensor to be shorter thanfactory length. Use the followingprocedure only if the tube sections aretoo long otherwise proceed to step d.

Refer to figure 2-28, disassemble and cutthe tube sections as follows:

1) Loosen and remove the 3/8 FNPT x 5/8

tube fitting and strain relief from the topof the sensor assembly. Carefully slidethe sensor wire out of the strain reliefgland.2) Loosen and remove the ¼ FNPT x ½tube fitting and sensor from the bottomof the sensor assembly. DO NOT removethe ½ inch tube from the 5/8 inch tube.

Figure 2-27. Top Mount Low Tank SwitchMounting Flange Cutout Dimensions

1.44 in.(37 mm)

0.72 in.(18 mm)

(4) Thru Holes0.281 in. (7 mm)

1.31 in.(33 mm)Dia. Thru

Hole

0.72 in.(18 mm)

1.44 in.(37 mm)

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Figure 2-28. Top Mount Low Tank SwitchAssembly Component Identification

STRAINRELIEF

STRAIN RELIEFGLAND NUT FLANGE AND

GASKET

SENSOR

¼ NPT X 1/8 FNPTBUSHING

¼ FNPT X ½ TUBEFITTING

½ TUBE X 5/8

TUBE UNION

1/2 FNPT X 5/8 TUBEFITTING

5/8 INCH O.D.STAINLESS TUBE

½ INCH O.D.STAINLESS TUBE

SENSORWIRE

3) Using a tubing cutter, remove therequired length of tube from the end ofeach tube. Deburr the cuts whencomplete.4) Install a new ½ compression ferruleon the end of the tube. Carefully threadthe sensor wire through the tubeassembly and attach the ¼ FNPT x ½tube fitting with sensor attached to theend of the tube. Tighten the ½ tubecompression nut.5) Install a new 5/8 compression ferruleon the end of the tube. Carefully threadthe sensor wire through the 3/8 FNPT x 5/8

tube fitting and strain relief gland.Attach the 3/8 FNPT x 5/8 tube fitting and

strain relief to the end of the tube.Tighten the 5/8 tube compression nut.6) Slide the flange to the top of the 5/8inch diameter tube and adjust thetelescoping section until the desiredlength is achieved as measured fromthe bottom of the flange to the bottomof the sensor. Tighten the compressionfittings on the union to lock length.

CAUTION: When extending the low tanksensor wires make sure the splices areproperly sealed using an adhesive filledheat shrink tubing.

LOW LEVEL SENSOR WIRING

CAUTION: When extending the low tanksensor wires make sure the splices areproperly sealed using an adhesive filledheat shrink tubing.

SINGLE FOAM TANK SYSTEMWhen a single foam tank system is installeduse minimum 16 AWG Type SXL or GXL (SAEJ1128) wire to extend the low tank sensorwire to allow connection to the 2-wirePackard WeatherPack connector on thedistribution box (see figure 2-23). Low tanklevel sensors are not polarity sensitivetherefore terminal connections are notspecific.

If necessary, when making splices to extendthe low tank sensor wires make sure thesplices are sealed using an adhesive filledheat shrink tubing. Where two wires exit theheat shrink tubing pinch the tubing whileheating the tubing to make sure theadhesive seals around both wires.

A connector kit (Hale P/N 546-1780-00-0) isincluded that contains a PackardWeatherPack 2-contact shroud half, two (2)14-16 gage male terminals and two (2) 14-16 gage cable seals. Assemble thesecomponents to the end of the low tanksensor wires. Snap the two halves of thePackard WeatherPack connector togethermaking sure they are sealed.

MINIMUM LENGTHWITHOUT CUTTING TUBESECTIONS 31-½ INCHES

(800 MM)

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DUAL FOAM TANK SYSTEMWhen the Hale FoamLogix system is installedusing a Hale ADT or Hale MDT ΙΙ connectthe low tank level sensors using the followingprocedure (refer to figure 2-29):

CAUTION: Before running wires from thelow tank switches to the A-B switch boxmake sure the wire from Tank A isidentified and properly labeled.

1. Using minimum 16 AWG Type SXL orGXL (SAE J1128) wire, extend the pigtailson the low tank level sensors to the A-Bswitch box. When making splices toextend the low tank sensor wires makesure the splices are sealed using anadhesive filled heat shrink tubing. Wheretwo wires exit the heat shrink tubingpinch the tubing while heating thetubing to make sure the adhesive sealsaround both wires.

CAUTION: Use the silicone sealerprovided with the Hale FoamLogixsystem to insulate the terminal stripconnection screws and preventcorrosion.

2. Tie one wire from each low levelswitch together as a common lead.Connect this common lead to the

center screw on the terminal block onthe A-B switch box.3. Connect the lead from Tank A to theterminal labeled A TANK on the switchbox and connect the wire from Tank B tothe terminal labeled B TANK.4. Seal the terminal strip connectionsusing the silicone sealer provided.

DISPLAY UNIT POWER AND GROUNDCONNECTIONS

Power must be connected directly tothe display unit. The power and groundconnection is the 2 pin packardconnector on the 12 inches long pigtailon the flow sensor harness (see figure 2-24). The mating harness provided isapproximately 18 inches long. Ifadditional wire length is required, useminimum 16 AWG type SXL, or GXL (SAEJ1128) wire.

Using the harness provided, connect theblack (B) wire to a chassis ground stud.Protect the ground connection fromcorrosion.

Connect the red (A) wire to the powersupply. Idealy this power wire should beconnected to a minimum 5 AMP fuseddedicated circuit. If a dedicated circuitis not available then the power lead canbe connected to a terminal where thereis not a high current load. Acceptableadditional components powered fromthis terminal include ENFO IV, Governor,Tank Level Gauge, Etc.

DISTRIBUTION BOX GROUND ANDPRIMARY POWER CONNECTIONS

CAUTION: Connect the primary positivelead from the terminal block to themaster switch terminal or relay terminalusing minimum 4 AWG type SGX (SAEJ1127) chemical resistant battery cableand protect with wire loom.

CAUTION: Prevent corrosion of powerand ground connections by sealingthese connections with silicone sealant

Figure 2-29. Low Tank Sensor A-BSwitchbox Connections

TANK BTERMINAL

COMMONTERMINAL

TANK ATERMINAL

A-B SWITCHBOX MOUNTED ONFOAM PUMP

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Figure 2-30. Extra Cable Storage

DON'TMODULAR CABLE

MODULAR CABLE

DOWIRE TIES

provided.

GROUND CONNECTIONBe sure the Hale FoamLogix system isgrounded to the chassis. Use a short lengthof wide flat ground strap at least 1-¼ inches(32 mm) wide and less than 18 inches (457mm) long to reduce the potential of RFIemitted by this connection. A stud labeledNEG (—) is located on the distribution box toattach the chassis ground strap to the HaleFoamLogix system. (See figure 2-24) Whenmaking the ground strap connections makesure lugs are attached to the strap ends fortrouble free connections.

When the length of the ground strapexceeds 18 inches (457 mm) use a widerstrap or a double thickness strap.

CAUTION: DO NOT connect the mainpower lead to small leads that aresupplying some other device such as alight bar or siren. The Hale FoamLogixModel 3.3 and Model 5.0 require 60 AMPminimum current. The Hale FoamLogixModel 3.0 requires 40 AMP minimumcurrent.

PRIMARY POWER SUPPLYCONNECTIONMake sure adequate switched electricalpower from the battery + terminal to thebattery connection stud on the distributionbox (see figure 2-24) is provided. Use 4AWG minimum type SGX (SAE J1127)battery cable directly to the battery,battery switch or solenoids for cable runs upto 6 feet (1.8 meters) long. Longer wire runsmay require larger battery cable for properoperation. DO NOT connect power to thesame connection as the pump primer. Thefollowing table provides recommendedcable size for various lengths of cable run.

Table 2-1

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RFI/EMIElectrically shielded cables for control unit,flowsensor, foam discharge multiplexingdisplay units and pressure transducers areprovided with the Hale FoamLogix system.The cables are 100% electrically shielded toeliminate the potential problem of EMI/RFI.Proper installation of system componentsand cables along with proper grounding willlimit radio interference caused by the HaleFoamLogix system. Additionally, make sureradio cables and hardware are not locatedin the immediate area where HaleFoamLogix equipment is mounted.

Make sure the flowsensor tee is grounded.If metal piping is used sufficient groundingmay be present. However, Victaulic joints,plastic pipe and rubber mounted pumpsinterfere with proper grounding and anadditional ground strap may be required. Ifnecessary, connect a flat braided groundstrap at least ¼ inch (6 mm) wide from theflowsensor tee to the apparatus frame to

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Figure 2-31. Remote Activation Switch Installation Dimensions

FOUR #10-32 UNC x 0.50 IN LGMOUNTING SCREWS AND NUTS

FOUR 0.203 IN.(5 MM) THRU

HOLES

0.88 IN.(22 MM)RADIUS

MOUNTINGPANEL

2.00 IN.(51 MM)

1.00 IN.(25 MM)

1.25 IN.(32 MM)

2.50 IN.(64 MM) 3.22 IN. (82 MM)

2.72 IN.(69 MM)

3.06 IN.(78 MM)

1.53 IN.(39 MM)

4.50 IN. (114 MM) MINIMUMCLEARANCE FOR CABLE

ensure proper grounding. The #6-32 UNCscrew that holds the spade terminal to theflowsensor tee can be used to attach theground strap to the tee (refer to figure 2-11).

Making round coils of extra control andflowsensor cables in the pumpcompartment can act as an antenna.While the control and flowsensor cablescannot be shortened, various lengths ofcable are available to minimize the "extra"cable in the truck. When routing controland flowsensor cables take care to avoidrouting them next to antenna wires, radiopower lines and radio components. Whenthere is extra cable, double the cable backon itself and secure with plastic wire ties in aflat bundle instead of making a round coil.(See Figure 2-30)

REMOTE ACTIVATION SWITCHChoose a location in the apparatuspersonnel compartment for mounting theremote activation switch. Make sure theswitch is accessible to the operator withoutinterfering with other controls on theapparatus.

To install the remote activation switch usethe following procedures (See Figure 2-31):

1. Determine location on panel whereswitch is to be mounted. Refer to figure2-33 and layout panel cutout andmounting holes as shown.

2. Make panel cutout and drill the four0.203 inch (5 mm) diameter thru holes.

3. Insert switch assembly through panel

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cutout and secure to panel using the#10-24 UNC x ½ inch long screws and#10-24 UNC nuts provided.

NOTE: When making cable connectionmake sure the cable is routed by theshortest most direct route. A maximumof 40 feet (12 meters) of remote cablemay be used.

4. Connect the remote activationswitch cable from the connector on thecontrol unit (see figure 2-24) to theconnector on the back of the remoteactivation switch.

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HALE FOAMLOGIX SYSTEM WITH MST

FLOWSENSORCABLE

CONTROLCABLE

LOW TANK LEVEL SENSORSUSE MINIMUM 16 AWG TYPE

SXL OR GXL (SAE J1128) WIRE

CONTROLUNIT

MST WIRINGHARNESS

MST SELECTOR

HALE FOAMLOGIX SYSTEM (NO TANK OPTION)

FLOWSENSORCABLE

CONTROLCABLE

LOW TANK LEVEL SENSORUSE MINIMUM 16 AWG TYPE


CONTROLUNIT

HALE FOAMLOGIX SYSTEM ELECTRICAL DIAGRAMS

GROUND STRAPUSE 1-¼ INCH WIDE FLAT BRAIDED GROUND STRAP

MAXIMUM 18 INCHES (457 mm) LONG

PRIMARY POWER SUPPLY CABLEUSE MINIMUM 4 AWG TYPE SGX (SAE J1127)

BATTERY CABLE FOR CABLE LENGTH UP TO 6 FEET.FOR CABLE LENGTH OVER 6 FEET REFER TO TABLE

2-2 FOR PROPER GAUGE WIRE.






REMOTE SWITCHCABLE

DISPLAY & POWER & GROUND

USE MINIMUM 16 AWG TYPE SXL

OR GXL (SAE J1128) WIRE

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HALE FOAMLOGIX SYSTEM WITH MDT ΙΙ

HALE FOAMLOGIX SYSTEM WITH ADT

FLOWSENSORCABLE

CONTROLCABLE


SXL OR GXL (SAE J1128)WIRE

CONTROLUNIT

ADT PANELPLACARD LIGHT

CONNECTION

FLOWSENSORCABLE

CONTROLCABLE



CONTROLUNIT

MDT �� WIRINGHARNESS

OPTIONALMDT �� WIRING

HARNESS EXTENSION

MDT ��SELECTOR

HALE FOAMLOGIX SYSTEM ELECTRICAL DIAGRAMS(Continued)







MAXIMUM 18 INCHES (457 mm) LONGPRIMARY POWER SUPPLY CABLE

USE MINIMUM 4 AWG TYPE SGX (SAE J1127)BATTERY CABLE FOR CABLE LENGTH UP TO 6 FEET.FOR CABLE LENGTH OVER 6 FEET REFER TO TABLE


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8

START-UP CHECKLISTBefore energizing the apparatus and Hale FoamLogix system for the first time make surethe following items are checked:

Electrical� Tank level sensor(s) wires connected to distribution box and sealed from moisture.� Tank level sensor(s) function properly.� Control cable connection at distribution box correct and tight.� Flowsensor cable properly connected to control unit.� All cables and wires are secured and protected from damage during operation.� Control and flowsensor cables properly folded and secured; radio antennas, power

lines and equipment away from cables.� Foam Pump and motor assembly properly grounded using flat ground strap.� Correct voltage provided. Direct current, negative ground.� Adequate current, 60 AMPS minimum, available. Main power direct to battery, battery

switch or solenoid without primer or other accessories tied in.� Primary electrical and ground connections tight and protected from corrosion with

silicone sealant.� Splices in wires sealed from moisture using adhesive filled heat shrink tubing.� Hale FoamLogix system ON/OFF switch on the distribution box is in the ON position.� If installed, ADT, MST or MDT ΙΙ electrical connections correct.� If installed, Remote ON/OFF switch cable connection correct.

Liquid� Flowsensor mounted with flow arrow in the correct direction for water flow.� Check valves are properly mounted in water and foam concentrate lines.� Strainer mounted for proper concentrate flow direction in foam tank to pump hose.� Foam tank to foam pump valve is in place and open.� Check valve/injector fitting lines are proper size and connections are tight.� BYPASS valve is properly mounted and oriented for direction of concentrate flow.� Foam concentrate gravity feeds to foam pump from foam concentrate tank.� All hoses free of kinks and sharp bends.� No sharp bends that can trap air exist in system.� MST positioned to FOAM TANK or MDT ΙΙ positioned to TANK A.� Flush water connections correct and tight.� Discharge piping hydro tested in accordance with NFPA/UL requirements.� Bypass valve handle is in the INJECT position.

Foam Pump� Foam pump and motor assembly mounted in horizontal position with base plate down.� Foam pump and motor assembly properly secured using proper mounting hardware.� Foam pump suction and discharge hoses connected to proper ports.� Foam pump suction and discharge hose fittings tight.

Optional ADT� Panel placard mounted on operator panel.� Air hoses connected and connections tight.� Selector switch is in the TANK A position.� Bypass handle is in the INJECT position.

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INITIAL SYSTEM POWER CHECKObserve the display on the control unitwhile energizing the apparatus electricalsystem and turn the foam pump distributionbox power switch to ON. Check the controlunit readout — FLOW, TOTAL FLOW, %FOAM, TOTAL FOAM and all bargraph LEDswill light along with "88888" for severalseconds. "HALE CLASS 1 2002" will scrollacross the display while the system checksitself followed by the default display. Thedefault display is zero on the digital readout(if no water is flowing) and FLOW LED (Seefigure 2-32). If default display does notappear refer to TROUBLESHOOTING forpossible causes and solutions.

INITIAL SYSTEM OPERATION CHECKAfter initial system power-up, low tank levelsensor operation, foam pump operationand flowsensor calibration must bechecked. Use the following procedures tocomplete these system checks.

CAUTION: Water is used at the systeminstaller facility to verify low tank level sensoroperation and foam pump operation as theend user specified foam concentrates maynot be readily available. DO NOT pumpwater with the Hale FoamLogix foam pumpfor more than one minute per foam tank.DO NOT attempt to calibrate foam pumpfeedback sensor with other than end userspecified foam concentrate. Make sure thebypass valve is in the BYPASS position whenpumping water with the foam pump.

1. Upon initial power-up with the foamtanks empty the display on the controlunit will alternate between "0" and "Lo A"indicating the foam tank is empty. Fillfoam concentrate tank A with water.The "Lo A" indication should disappearfrom the control unit display indicatingthe low tank level sensor in Tank A isoperating properly.

When energizing the Hale FoamLogix system at the system installer facility for the first timethe following procedures shall be used.

Figure 2-32. Control Unit Ready Indication

WARM-UP/SYSTEM CHECKING

SYSTEM READY

SYSTEM INSTALLER START-UP

INITIAL POWER-UP

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2. If the system is equipped with ADT orMDT ΙΙ move the selector to TANK Bposition and observe the control unitdisplay. The display should alternatebetween "0" and "Lo b" indicating thefoam tank is empty. Fill foamconcentrate tank B with water. The "Lob" indication should disappear from thecontrol unit display indicating the lowtank level sensor in Tank B is operatingproperly.

3. If the system is equipped with ADT,MDT ΙΙ or MST place the selector in theFLUSH position. "FLUSH" should alternatewith "0" on the control unit display. Onceproper operation is verified place theselector to TANK A position (or FOAMTANK position on MST).

NOTE: The bypass valve on the ADT is apull to operate device. There are twodetents that the valve must pass throughto be fully open. Make sure the bypassvalve is fully opened before attemptingto operate foam pump.

4. Place the BYPASS valve to theBYPASS position to check foam pumpoperation. Place a calibrated fivegallon container at the discharge of thebypass hose.

5. Place the system in simulated flowmode by selecting the FLOW display anddepressing both up � and down �buttons simultaneously. Set simulatedflow value to 100 GPM by pressing up �or down � button. Display will show “S”at the left most position to indicate thesimulated flow (See figure 2-33).

6. Depress the SELECT DISPLAY buttonuntil the LED under % FOAM lights. Setfoam concentrate injection rate to "1.0"by pressing up � or down � button.

7. Depress the SELECT DISPLAY buttonuntil the LED under TOTAL FOAM lights.

Figure 2-33. Simulated Flow Display

Depress ON button to energize HaleFoamLogix system. Observe thedischarge of the bypass hose to makesure the foam pump is operating. Afterone minute depress the ON button tostop the foam pump. There should beapproximately one gallon of water inthe container and the TOTAL FOAMdisplay on the control unit should readapproximately "1.0".

8. If the system is equipped with ADT orMDT ΙΙ move the selector to TANK Bposition and repeat steps 6 and 7 fortank B.

9. After foam pump operation hasbeen checked with both foam tanks exitsimulated flow mode by selecting theFLOW display and depressing both up �and down � buttons simultaneously.

10. Drain water from foam tanks andconcentrate lines and return the bypassvalve to the INJECT position.

11. Verify operation of and calibrateflowsensor(s) as required usingflowsensor calibration procedures in theuser calibration section.

This completes the Hale FoamLogix systemoperation checks that can beaccomplished at the system installer facility.Foam pump feedback calibration along

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with setting of user specified defaultsimulated flow and concentrate injectionrates should be accomplished upondelivery to the end user using actual enduser specified foam concentrates anddefault values.




FoamLogix��

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SECTION IIISET-UP AND CALIBRATION

NOTICE: This manual section is used by the installer and end user for setting up and calibratingthe Hale foam proportioning system. This manual section also provides procedures for the enduser to change default values and verify calibration if different foam concentrates are used. Thismanual section can be used as a stand alone section or in conjunction with other sections of thecomplete manual.

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Section ��: Set-up and Calibration














5. Do not mount radio transmitter or

transmitter cables in direct or closecontact with the FoamLogix control unit.







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8. The system can only perform when theelectrical connections are sound, somake sure each one is correct.

9. The cables shipped with each HaleFoam system are 100% tested at thefactory with that unit. Improper

handling and forcing connections candamage these cables which could resultin other system damage.

10. There are no user servicable parts insideHale Foam system electrical/electroniccomponents. Opening of thesecomponents (distribution box, controlunit, foam discharge multiplexing displayunit) will void warranty.







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INSTALLATION AND DELIVERY CHECKLIST

After the Hale FoamLogix system has been installed the following check list should be usedto verify installation and ensure proper system set-up when apparatus is delivered to theend user. Use procedures in referenced manual sections.

INSTALLATIONDATE INITIALS

_______ _______ � System properly installed according to installation section ofmanual. (SECTION II; START-UP CHECKLIST)

_______ _______ � Tank level sensor function verified for Tank A and Tank B (asequipped). (SECTION II; SYSTEM INSTALLER START-UP)

_______ _______ � Foam pump operation checked for both Tank A and Tank B (asequipped). (SECTION II; SYSTEM INSTALLER START-UP)

_______ _______ � Flush indication on control unit display verified. (SECTION II; SYSTEMINSTALLER START-UP)

_______ _______ � Foam tank(s) and hoses drained of water. (SECTION II; SYSTEMINSTALLER START-UP)

_______ _______ � Flowsensor function checked and flowsensor calibrated asnecessary. (SECTION III; USER CALIBRATION)

DELIVERYDATE INITIALS

_______ _______ � Foam tank(s) filled with user specified foam concentrate(s).(SECTION III; INITIAL END USER SET-UP)

_______ _______ � Foam pump priming checked for both foam concentrate tank(s).(SECTION III; INITIAL END USER SET-UP)

_______ _______ � Flowsensor calibration verified with pitot. (SECTION III; USERCALIBRATION)

_______ _______ � Default simulated flow value set to end user specification.(SECTION III; USER CALIBRATION)

_______ _______ � Default foam concentrate injection rate(s) set to end userspecification for each foam tank (as equipped). (SECTION III; USERCALIBRATION)

_______ _______ � Foam concentrate feedback values verified and calibrated withend user specified foam concentrate(s). (SECTION III; USERCALIBRATION)

_______ _______ � Proper Hale FoamLogix system operation demonstrated to enduser in accordance with manual procedures. (SECTION IV;OPERATING INSTRUCTIONS)

_______ _______ � End user trained in proper operation of Hale FoamLogix system inaccordance with manual procedures. (SECTION IV; OPERATINGINSTRUCTIONS)

_______ _______ � Warranty registration card filled out by end user and mailed toHale Products Inc.

_______ _______ � Two copies of Description, Installation and Operation manualprovided to end user.

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When the apparatus is delivered to the enduser facility the foam tank(s) must be filledwith the specified foam concentrate(s).Make sure the proper foam concentrate isput into the correct tank. The system mustthen be adjusted to operate with the enduser foam concentrate(s) for bestaccuracy.

SYSTEM POWER CHECKObserve the display on the control unitwhile energizing the apparatus electricalsystem and turn the foam pump distributionbox power switch to ON. Check the controlunit readout — FLOW, TOTAL FLOW, %FOAM, TOTAL FOAM and all bargraph LEDswill light along with "88888" for severalseconds. "HALE CLASS 1 2002" followed bythe software revision level (r x.x) will scrollacross the display while the system checksitself followed by the flow display. The flowdisplay is zero on the digital readout (if nowater is flowing) and FLOW LED (See figure2-33). If flow display does not appear referto TROUBLESHOOTING for possible causesand solutions.

PRIMING FOAM PUMPAfter the foam tank(s) are filled and thesystem is powered up foam concentrateflow must be checked to verify the foampump is primed.

CAUTION: When operating the HaleFoamLogix in Simulated Flow mode anoutlet for the foam concentrate must beprovided to prevent excessive pressurebuildup in discharge piping or hoses.

1. Make sure the bypass valve is in theBYPASS position. Route the bypass hoseinto a suitable container to collect thedischarged foam concentrate.

2. If dual foam tank system is used selectTANK A. Make sure there is foamconcentrate in both foam tanks.

INITIAL END USER SET-UP

Figure 3-1. Control Unit Ready Indication

WARM-UP/SYSTEM CHECKING

SYSTEM READY

INITIAL POWER-UP

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3. Place the system in simulated flow modeby selecting the FLOW display anddepressing both up ��and down �buttons simultaneously. Increasesimulated flow value by pressing �button to permit easier priming (abovefactory default value of 150 GPM).Display will show “S” at the left mostposition to indicate the simulated flow(See figure 3-2).

4. Engage the Hale FoamLogix system bypressing the red ON button. The left LEDon the horizontal bargraph will illuminateto indicate the system is on. As the foampump begins to run the bargraph LEDsto the right light indicating foamconcentrate is being pumped. If noconcentrate is flowing the pump willincrease to maximum speed in anattempt to prime itself. All LEDs will lightand flash. The pump will run at fullspeed until a feedback signal isindicated or for 30 seconds. If nofeedback signal is present after 30seconds the system will shut down andthe display will show "noPri" (no prime).Repeat this step one more time toattempt to prime the pump.

If the foam pump does not prime afterthe second try do the following:

• Make sure all foam concentratevalves are open.

• Make sure there are no restrictions inthe hose from the foam concentratetank to the inlet of the foam pump.

• Make sure there are no air traps inthe hose from the foam concentratetank to the inlet of the foam pump.

• Make sure there are no leaks in theplumbing where air can enter the pump.

Figure 3-2. Simulated Flow Display

5. If the system has been installedproperly, foam concentrate should flowreadily to the pump. Observe the clearfoam suction line to verify if foam isflowing.

6. If a dual tank system is installed switchto TANK B and repeat primingprocedure for that tank.

7. Once foam flow is established fromboth tanks, turn the system off and turnthe bypass valve back to the INJECTposition.

Proceed with user calibration proceduresas system calibration must now be verifiedwith the end user foam concentrate.

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USER CALIBRATIONThe complete Hale FoamLogix System;foam pump and motor assembly, controlunit and flowsensor, is tested and calibratedat the factory before shipping to theinstaller. Each component of the matchedsystem is assigned the same serial numberto ensure they remain together. If the HaleFoamLogix system is properly installed,further calibration WILL NOT be necessaryuntil delivery to customer. The system isdesigned to permit easy checking ofcomponent calibration to assure accurateoperation. The calibration verificationprocess will verify component calibrationand allow adjustments to the flowsensorand feedback sensor display readings toallow for variations in apparatus pipingconfiguration and end user selected foamconcentrate(s). Default values forsimulated flow and foam concentrateinjection rates can be set to end userspecifications while in the calibration mode.

NOTE: The Hale FoamLogix system iscalibrated at the factory to U.S.measurement (GPM, PSI, GALLONS, etc.)units. The system may be calibrated toany unit of measure, i.e. U.S., Metric,Imperial, etc. The same unit ofmeasurement must be used throughoutthe calibration process to ensure properproportioning by the system.

Recalibration of the system should berequired ONLY after major repairs orcomponent changes to the HaleFoamLogix foam system or if differentviscosity foam concentrates are used.

ENTERING PASSWORDSEntering passwords is accomplished byusing the control unit function buttons.

To enter passwords press and hold theDISPLAY button. The display will show PASSthen go blank. While continuing to hold the

display button press the � or � button toenter the password.

RESTORE FACTORY DEFAULT VALUESAt times it may be necessary to return thesimulated flow rate, concentrate injectionrate(s) and calibration factors to the originalfactory default values.

To return to the factory default values enterthe restore factory values password(��) as previously described. Once thepassword is entered correctly the unit willdisplay "FAC" and return to normaloperation. Proceed with calibration afterperforming this reset.

Factory default values are:Simulated Flow: 150 GPM (568 LPM)% FOAM: 0.5% Class A (Tank A)

1.0% Class B (Tank B) (If soequipped)

CALIBRATIONTo perform calibration the unit must beplaced in calibration mode with the properpassword.

To enter calibration password press andhold the DISPLAY button. The display willshow "PASS" then go blank. Whilecontinuing to hold the display button enterthe calibration password (��).

The display will show “CAL” (See figure 3-3)for several seconds followed by "C 0" andFLOW LED (Water Flowsensor Calibration).(See figure 3-4)

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WATER FLOWSENSOR CALIBRATIONNOTE: The flowsensor is calibrated atHale Products Inc. and matched to thecontrol unit. If the system is installedproperly only minor adjustments shouldbe necessary to flowsensor reading.

Flowsensor calibration should be verifiedduring NFPA/UL testing of apparatus anddelivery to end user.

NOTE: An accurate flow measuringdevice must be used to measure thewater flow when calibrating theflowsensor. Use a suitable size smoothbore nozzle and an accurate PitotGauge instrument. Hand held pitotgauges are usually not very accurate.Make sure the system is calibrated withan accurate flow measuring device.

Determine the water flow normallyexpected from the discharge outlet andestablish flow. Make sure the water flowestablished is within the range of theflowsensor monitoring the discharge. Forexample, actually establish a flow of 150GPM (568 LPM) of water through a nozzleand Pitot system. Compare the calculatedflow value to the value shown on thecontrol unit digital display.

Press the � or � button to set the readingto match the actual flow calculated fromthe Pitot gauge reading. Decrease firepump pressure by approximately ½ andrecalculate water flow rate. Verify thereading on the control unit is within 5% ofthe actual value. Stop the water flow whenthe reading adjustments are completed.

Figure 3-4. Flowsensor Calibration Display

Figure 3-3. Entering Calibration Mode

RELEASE WHENDISPLAY SHOWS

"CALIB"

PRESS ANDHOLD

CONTINUE TOHOLD

DISPLAYS WHEN� IS PRESSED

DISPLAYS WHEN� IS PRESSED

PRESS INSEQUENCE AS

NECESSARY TOENTER

PASSWORD

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Figure 3-6. Simulated Flow CalibrationDisplay

RECORD WATER FLOWSENSORCALIBRATION FACTORDepress and release the DISPLAY button.The display will show "F xx.x" which is thewater flowsensor calibration factor (Seefigure 3-5). Record this value for futurereference. This factor can be programmedinto the display if the display ever requiresreplacement.WATER FLOWSENSOR CALIBRATIONFACTOR: _________________________

SIMULATED FLOWThe default Simulated Flow value is factoryset to 150 GPM (568 LPM) and, if necessary,the default value can be adjusted while inuser calibration mode. Press the DISPLAYbutton. The default simulated flow rate willbe displayed as shown in figure 3-6. Adjustthe setting by pressing the � or � buttons toset the desired rate, i.e., “S 150”.

FOAM CONCENTRATE INJECTION RATEWhen the Hale FoamLogix system power isturned on, the foam concentrate injectionrate in memory will be the default injectionrate setting. The user specific defaultconcentrate injection rate can be adjustedin calibration mode.

Press the DISPLAY button. The display willshow the current default concentrateinjection rate stored in the computermemory for the selected foam concentratetank (see figure 3-7). If the factory defaultvalues have not been changed the displaywill show “PA 0.5” for a single tank system ordual tank system with selector in the TANK Aposition. When a dual tank system isinstalled and the selector is placed in theTANK B position the display will show "Pb1.0". The � or � buttons can be used to setthe user specified default concentrateinjection rate.

If a dual tank system is installed set thedefault injection rate with the tank selectorin the TANK A position then switch to theTANK B position to set concentrate injectionrate for the foam concentrate in thatparticular tank.

If the ADT, MDT ΙΙ or MST selector is in theFLUSH position the display will show "FLUSH"and the foam concentrate injection ratecannot be set.

FOAM PUMP FEEDBACK CALIBRATIONNOTE: Foam pump feedback iscalibrated at Hale Products Inc.Calibration after installation is necessaryto verify values with the actual foamconcentrate(s) being used. Onlycalibrate using actual foam

Figure 3-5. Flowsensor Calibration FactorDisplay

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NOTE: If an accurate calibratedcontainer is not available an accuratescale can be used to weigh the foamconcentrate pumped. The total volume

concentrates. DO NOT use water,training or test foams for feedbackcalibration verification.

Press the DISPLAY button. The control unitdisplay will show "A x.xx" for a single tanksystem or dual tanks system with theselector in Class A position or "B x.xx" for dualtank system with the selector in Tank Bposition, indicating the total volume offoam concentrate pumped during the lastcalibration run (See figure 3-8).

Set the bypass valve to the BYPASS positionand place a graduated measure containerat the outlet of the bypass hose that cancontain the expected volume of foamconcentrate, 5 gallons (19 liters) minimum(figure 3-9). Figure 3-9. Foam Concentrate Collection

CALIBRATEDCONTAINER

BYPASSVALVE ON

FOAM PUMP

BYPASSHOSE

Figure 3-8. Foam Pump FeedbackCalibration DisplayFigure 3-7. Foam Concentrate Injection

Rate Default Value Set Display

TANK SELECTOR (TANK B)

TANK SELECTOR (TANK A)



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of foam concentrate can then becalculated from this weight and thedensity of the foam concentrate fromthe MSDS sheet.

Start the Hale FoamLogix foam pump bypressing the red ON button. The LEDs on thehorizontal bargraph will light and the foampump will operate at approximately 2/3

speed to pump foam concentrate into thecontainer. The display will show the volumeof foam concentrate pumped. Stop thefoam pump and measure precisely theamount of foam concentrate collected.

Adjust the reading on the display to thevolume actually pumped by pressing the �or � button.

Repeat the procedure to verify the setting iscorrect.

When a dual tank system is installed switchto the other tank and repeat theprocedure.

Set the bypass valve handle back to INJECTposition.

RECORD FOAM PUMP FEEDBACKCALIBRATION FACTORS

Depress and release the DISPLAY button.The display will show "FAxxx" for single tankor dual tank system with selector in Class Aposition or "FBxxx" for dual tank system withselector in Class B position (See figure 3-10).These are the foam pump feedbackcalibration factors. Record these values forfuture reference. These factors can beprogrammed into the display if the displayever requires replacement.Class A FOAM PUMP FEEDBACKCALIBRATION FACTOR: ____________Class B FOAM PUMP FEEDBACKCALIBRATION FACTOR: ____________

EXITING AND SAVING CALIBRATIONTo exit calibration and save the set valuespress and hold the DISPLAY button. Thedisplay will show "PASS" then go blank.While continuing to hold the display buttonenter the password (��).

The display will show “SCAL” (See figure 3-11) for several seconds followed by the flowdisplay "C 0".

The above procedures completeverification and adjustment of the system.The Hale FoamLogix system is now ready tobe placed in service.

Figure 3-10. Foam Pump FeedbackCalibration Factor



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Figure 3-12. Relief Valve

FOAMLOGIXFOAM PUMPASSEMBLY

DISTRIBUTIONBOX

ELECTRICMOTOR

PRESET RELIEFVALVE

RELIEF VALVEThe pressure relief valve (see figure 3-12) isfactory tested and set to values shown inthe following table. During normalinstallation and operation the relief valvewill not require adjustment. If adjustment isnecessary in field installation contact HaleProducts Inc for Relief Valve Service bulletin.

Figure 3-11. Exiting and SavingCalibration

RETSAMMAOFELAHLEDOM

TESEVLAVFEILERERUSSERP

0.5LEDOM )RAB12(ISP003

3.3LEDOM )RAB82(ISP004

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FoamLogix��

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SECTION IVOPERATION

NOTICE: This manual section is primarily used by the apparatus end user for proper operationand maintenance of the Hale foam proportioning system. This manual section can be used as astand alone section or in conjunction with other sections of the complete manual.

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Section ��: Operation




2. To prevent electrical shock alwaysdisconnect the primary power sourcebefore attempting to service any part ofthe Hale FoamLogix system.


4. To prevent system damage or electricalshock the main power supply wire will bethe last connection made to the HaleFoamLogix distribution box.


6. Rotating drive line components cancause injury. When working oncomponents of the Hale FoamLogixsystem be careful of rotatingcomponents.


utilized to protect the Hale FoamLogixfrom dry running. Failure to use low levelsensors with the Hale FoamLogix systemwill void warranty.



4. Hale FoamLogix systems are designedfor use on negative ground directcurrent electrical systems only.

5. Do not mount radio transmitter ortransmitter cables in direct or closecontact with the Hale FoamLogix unit.







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2. Ensure that the electrical source ofpower for the unit is a negative groundDC system, of correct input voltage, witha reserve minimum current available todrive Hale FoamLogix system.


4. When determining the location of HaleFoamLogix components keep in mindpiping runs, cable routing and otherinterferences that will hinder or interferewith proper system performance.

5. The Hale HPF flowsensor is assembledand tested at the factory. Removal ofthe flow sensor from the tee is notnecessary or recommended forinstallation in the system.


7. The cordsets provided with each HaleFoamLogix system are 100% electricallyshielded assemblies. Never attempt toshorten or lengthen the molded cables.If necessary order longer or shortercordsets from Hale Products to suit theparticular installation.

8. The cordsets provided with each HaleFoamLogix system are indexed so theyonly go in the correct receptacle andthey can only go in one way. Whenmaking cordset connections DO NOTforce mismatched connections asdamage can result in improper system

operation.9. The system can only perform when the

electrical connections are sound, somake sure each one is correct.

10. The cables shipped with each HaleFoamLogix system are 100% tested atthe factory with that unit. Improperhandling and forcing connections candamage these cables which could resultin other system damage.

11. There are no user serviceable partsinside Hale FoamLogix system electrical/electronic components. Opening ofthese components (distribution box,control unit, foam discharge multiplexingdisplay unit) will void warranty.


13. When making wire connections makesure they are properly insulated andsealed using an adhesive filled heatshrink tubing.





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Figure 4-1. Control Unit Identification

BARGRAPH(LIGHTS TO INDICATE THE SYSTEM

IS ON AND INJECTING FOAMCONCENTRATE)

ON PUSH BUTTON(TURNS THE FOAM INJECTION ON

OR OFF.)

DOWN ARROW AND UP ARROW(ADJUST THE CONCENTRATE INJECTION RATE DURING OPERATION. PUSHING

BOTH AT THE SAME TIME WILL RESET TOTAL FOAM OR FLOW VALUES)

LEDs(LIGHT TO INDICATE FUNCTION

SELECTED)

DISPLAY(SELECTS CONTROL UNIT

FUNCTION AS INDICATED BYLABEL AND LED AT LEFT)

OPERATING INSTRUCTIONSSYSTEM OPERATION DESCRIPTIONOperation of Hale FoamLogix systems issimple with all control provided by the pushbuttons on the control unit face (see figure4-1).

Upon initial power up of the apparatus theHale FoamLogix system will go to thestandby mode upon completion of a selfdiagnostic routine. There are four differentdisplay functions on the control unit digitaldisplay. While in standby mode with theFLOW LED lit the digital readout will show thecurrent water flow rate in the monitoreddischarge pipe. Pressing the DISPLAYbutton will change the function indicatedby the LED that is lit under a particular label.TOTAL WATER and TOTAL FOAM values canbe reset any time they are displayed.When the % FOAM LED is lit, or in any otherfunction mode, the foam concentrateinjection rate can be set to the desiredvalue, if different from the default value,

prior to or during foam operations bypressing the � and � buttons.

When the red ON button is pressed, theleftmost LED will illuminate indicating thatthe system is ready. If water flow is presentthe foam pump will start and inject foamconcentrate into the discharge stream. Thebargraph will light when foam is beinginjected and indicate system capacity. TheHale FoamLogix system constantly monitorswater and foam concentrate flow valuesmaintaining foam injection at the specifiedconcentrate injection rate. The systemresponds to variations in water flow byincreasing or decreasing the speed of thefoam pump.

When the ON button is again pressed, theLEDs will extinguish, indicating that thesystem is in Stand-By mode and the foampump will stop, but other system monitoringfunctions will continue.

DIGITAL DISPLAY(PROVIDES DIRECT READOUT OF

SELECTED FUNCTION VALUES ANDDISPLAYS WARNINGS)

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TANK B SELECTED

TANK A SELECTED

Figure 4-3. Foam Percentage Display

DISPLAY INFORMATIONThe five digit display on the control unitshows the value of the selected displayfunction or provides warnings to theoperator when the system is operating. Afunction is selected by pressing the greyDISPLAY button in the upper right handcorner of the control unit. Each time thebutton is pressed a new function mode isselected and displayed. LEDs above thedigital display denote which function isbeing displayed. Pressing the SELECTDISPLAY button changes the control unitfunction but does not affect injection rate.

Control unit functions include:FLOWThe display shows the current flow rateof water or foam solution per minute inHale flowsensor monitored discharges.(See figure 4-2)

% FOAMThe display shows the foam concentrateinjection rate setting in the % FOAMmode. For example, with a single tanksystem or when the dual tank systemselector is in the TANK A position thedisplay will show "A 0.5". When the dualtank system selector is in the TANK Bposition the display will show "b 1.0".(See figure 4-3) When the system isequipped with MST, MDT ΙΙ or ADT and

the selector is in the flush position thedisplay reads "FLUSH".

TOTAL FLOWThe display shows the total amount ofwater or foam solution pumped throughflowsensor monitored discharges. Thistotalized value may be reset usingprocedures outlined in the "ResetFunctions" paragraph.

TOTAL FOAMThe display shows the total amount offoam concentrate pumped. The valuewill be in the same unit of measure asthe water flow. This totalized value maybe reset using procedures outlined in the"Reset Functions" paragraph. As anexample the display may show "9.5"indicating 9.5 gallons of foam

Figure 4-2. Stand-By/Flow Mode Display

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concentrate have been used. (Seefigure 4-4)

BARGRAPHThe bargraph (refer to figure 4-1) consists of10 LEDs. When the ON button is pressed theleftmost LED will light to indicate the systemis on and ready to inject foam concentrate.When water is flowing LEDs to the right onthe bargraph will light indicating foamconcentrate is being injected. The amountof LEDs lighted provides an indication of theapproximate pump capacity being used.

If water flow requirements exceed thecapacity of the pump to deliver foamconcentrate, the pump will run at maximumrate. All bargraph LEDs light and therightmost LED flashes warning the operatorthat the system capacity is being exceededand is running "lean" on foam concentratepercentage.

If the flow decreases such that the requiredinjection rate is less than the lowest rating ofthe pump, the pump will run at its minimumrate and the first bargraph LED to the rightflashes so the operator will know the systemis running "rich" on foam percentage.

RESET FUNCTIONSThe totalized values for water and foamconcentrate pumped can be cleared frommemory by performing a RESET function.

Using the DISPLAY button, select eitherTOTAL WATER or TOTAL FOAM. By pressingand holding both the � and � buttons atthe same time, the value shown is clearedand displayed as zero. Additionally thetotalized values for water and foamconcentrate reset to zero automaticallywhen the apparatus power is turned off.

FOAM CONCENTRATE INJECTION RATEWhen % FOAM is selected, the � and �buttons will respectively increase ordecrease foam concentrate percentage.

While operating in any function, with theexception of FLOW during simulated flowoperation, whenever the � or � buttonsare momentarily pressed, the display willswitch to the % FOAM display and show thecurrent injection rate for 2 seconds. In anydisplay mode, if either the � or � button isheld down for a period of 2 seconds ormore, the injection rate value will increaseor decrease accordingly. Once released,the display will return to the last selecteddisplay after 2 seconds. When a reset(pressing both the � and � buttons at thesame time) is performed in the % FOAMdisplay mode the foam concentrateinjection rate is returned to the defaultvalue.

WARNING MESSAGESSeveral safety features are incorporatedinto the Hale FoamLogix system to protectthe foam concentrate pump, electric motorand apparatus wiring while maintainingpersonnel safety. Messages appearing onthe display alert the operator to adverseconditions that could cause damage toHale FoamLogix system components, theapparatus and cause personnel injury.

FLUSHIf the Hale FoamLogix system is equippedwith ADT, MDT ΙΙ or MST and the operatingcontrols for these selectors are in the FLUSHposition the foam pump motor will increaseto approximately 80% capacity. The systemwill operate for 20 seconds when water is

Figure 4-4. Total Foam Display

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flowing then go to standby mode.

When in FLOW or TOTAL FLOW mode thedisplay will alternate between "FLUSH" (seefigure 4-5) and the value of the selectedfunction. These modes function normallywhen in FLUSH mode.

When in % FOAM or TOTAL FOAM mode"FLUSH" will show steady on the display.These modes will not function while in FLUSHmode.

Low Foam Tank LevelThe Hale FoamLogix foam pump isinterlocked with the foam concentrate tanklevel switch(es). If the tank is empty, thepump will run for 1 minute. Low foamconcentrate tank level is denoted by “LoA” or “Lo b” (see figure 4-6) alternating withthe normal selected function on the display.If one minute of low concentrate level is

detected the display will show “no A” or“no b”, the pump will stop, and the leftmostLED will go out until the foam level isrestored and the ON button is depressed. Ifthe ON button is pressed before refilling thefoam tank the system will run for 30 seconds

Figure 4-5. Flush Display

Figure 4-6. Low Foam Tank Display

TANK ASELECTED

AFTER 1MINUTE OFOPERATION

TANK BSELECTED

AFTER 1MINUTE OFOPERATION

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before shutting down again.

Priming ErrorIn the event there is no feedback signalbeing received when the foam pump isstarted, indicating a lack of foamconcentrate flow, the foam pump motorwill run at full speed to attempt to establishfoam concentrate flow. If the systemoperates for a period of 30 seconds withouta feedback signal the system will go to thestandby mode and the display will flash“noPri” (no prime) indicating there is nofoam concentrate flow. (See figure 4-7)

High Ambient TemperatureIn the event the Hale FoamLogix system isoperating in an environment of excessiveambient temperature the display will show“hiGh” to indicate this situation (see figure4-8). If the circuitry in the Hale FoamLogixsystem is being affected by a drop in powersupply voltage the display will show “Lo SP”to indicate this situation.

NOTE: This is not necessarily anindication of apparatus battery level orcondition. This is only an indication ofadverse operating conditions. Forinstance a bad battery cable cancause the system to see low power eventhough the batteries are fully charged.

In either case the system will continue to runwith these adverse conditions. If conditionsdeteriorate to the point of potential systemdamage due to heat or low power thesystem will return to the standby and errormessage will remain until ON is pushedagain.

Figure 4-7. Priming Error Display

Figure 4-8. High Temperature and LowBattery Display

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NORMAL OPERATION SUMMARY

OPERATION ACTION DISPLAY

INITIAL STARTUP

SELF DIAGNOSTICS

STANDBY DISPLAYSINGLE FLOWSENSOR: FLOW

MULTIPLE FLOWSENSORS: % FOAM

WATER FLOW ESTABLISHED, ON BUTTONPRESSED

Begin Foam Injection Establish water flow anddepress ON button.

Energize System Energize apparatus and turnFoamLogix power switch toON.

Select foam tank If System equipped with dualfoam tanks place selector toproper tank.

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FOAM CONCENTRATE INJECTION RATEDISPLAY

TOTAL FOAM DISPLAY

TOTAL FLOW DISPLAY

End foam injection Depress ON button.

Read total foam Press DISPLAY untilconcentrate LED below TOTAL FOAM is lit.

Read total water Press DISPLAY untilor foam solution LED below TOTAL FLOW is lit.

Change injection rate Press � or � and hold for 2seconds. Release oncedesired rate is set.

OPERATION ACTION DISPLAY

Reset Totalized values While in TOTAL FLOW orTOTAL FOAM press andrelease � and �.

Read injection rate Press and release � or �.Display will show injectionrate and return to selectedfunction after 2 seconds.

STANDBY DISPLAYSINGLE FLOWSENSOR: FLOW

MULTIPLE FLOWSENSORS: % FOAM

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The Simulated Flow mode of the HaleFoamLogix system allows the operator tooperate the foam pump withoutdischarging water through a foam capabledischarge or when the flowsensor is notfunctioning. The simulated flow mode isused for draining the foam tank forcleaning, checking calibration of thefeedback sensor, verifying foam pumpoperation or manually controlling foaminjection if the flowsensor malfunctions. Thefactory default simulated flow rate is 150GPM (568 LPM). The simulated flow rateand the concentrate injection percentagerate can be set by using the displayreadout and the rate adjustment buttonson the control unit while in simulated flowmode. The simulated flow function providesmanual operation of the foam injectionsystem required by NFPA standards.

CAUTION: When operating the HaleFoamLogix in Simulated Flow mode anoutlet for the foam concentrate must beprovided to prevent excessive pressurebuildup in discharge piping or hoses.

Use the following procedure to operate theHale FoamLogix system using simulatedflow:

SIMULATED FLOW OPERATION1. Locate the bypass hose and uncoilto place the end into a suitablecontainer to collect the foamconcentrate.2. Place the Hale FoamLogix systemBYPASS valve in the BYPASS position.3. Energize apparatus electrical systemand turn Hale FoamLogix power switchto ON.4. When the Hale FoamLogix is in thestandby mode, FLOW LED lit, depressand release the � and � buttons at thesame time. The display will show "S 150"(or other preset default value) and theFLOW LED will be lit. (see figure 4-9)5. Depress the ON button. The leftmostLED will light and the foam pump willbegin running. Foam concentrate willflow out of the end of the bypass hose.6. To end simulated flow operation, firstdepress the ON button to stop the foampump.7. Press DISPLAY button until the FLOWLED is lit.8. Depress and release the � and �buttons at the same time. The displaywill show the current water flow valueand the FLOW LED will be lit.9. Deenergize apparatus electricalsystem.

Figure 4-9. Simulated Flow Operation Display

SIMULTANEOUSLYPRESS AND RELEASE

ENTERING SIMULATED FLOW MODE SIMULATED FLOW MODE DISPLAY

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10. Place the bypass valve to the INJECTposition. Secure bypass hose in theappropriate compartment.11. Return apparatus to normal readycondition.

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TANK SELECTION WITH DUAL TANKSYSTEMThe following procedures are provided foroperation of the Hale FoamLogix systemwith a Hale ADT or Hale MDT ΙΙ Selectorinstalled.

CAUTION: Unless engaged in Class Bfoam operations, the Hale FoamLogixADT toggle switch or Hale FoamLogixMDT ΙΙ selector handle must be in theTANK A position. If the toggle switch orselector handle is in the FLUSH positionwhen the Hale FoamLogix foam pump isstarted the foam pump will only run for20 seconds and shut down.

1. Make sure the Hale FoamLogix isoperating and foam solution is beingdischarged.

2. Flip the Hale ADT toggle switch down orturn the Hale FoamLogix MDT ΙΙ handle untilthe indicator points toward the desired tank(See figure 4-10). When changing toggleswitch or selector handle position, movesmoothly from the TANK A position throughthe FLUSH position to TANK B position in onemotion without stopping. With the firepump discharging water and the HaleFoamLogix operating, a small volume ofwater will be provided to separate the twofoam types helping to prevent possiblereactions.

SELECTOR SHOWNIN FLUSH POSITION

SELECTOR SHOWN INTANK B POSITION

SELECTOR SHOWN INTANK A POSITION

(NORMAL OPERATINGPOSITION)

VALVEPOSITION

INDICATOR

SELECTORHANDLE

Figure 4-10. Dual Tank Selector Operating PositionsHALE FOAMLOGIX MDT ΙΙ

TOGGLE SWITCHSHOWN IN FLUSH

POSITION

TOGGLE SWITCHSHOWN IN TANK B

POSITION

TOGGLE SWITCH SHOWNIN TANK A POSITION

(NORMAL OPERATINGPOSITION)

TANK AINDICATOR

LIGHT(GREEN)

TOGGLESWITCH

HALE FOAMLOGIX ADT PLACARD

TANK BINDICATOR

LIGHT(RED)

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3. After completion of Class B foamoperations briefly flush the foam pump andreturn the Hale FoamLogix to the readycondition by returning to the TANK Aposition and flowing a small amount ofClass A foam concentrate.

IMPORTANT: Make sure the HaleFoamLogix dual tank system is in theTANK A position when apparatus isplaced in ready condition.

FLUSHING HALE FOAMLOGIXWhen returning the apparatus to readycondition after foam operations using classB foam, the Hale FoamLogix foam pumpmust be flushed because some Class Bfoam concentrates deteriorate rapidly.

NOTE: Approved class A foamconcentrates do not deteriorate rapidlylike class B foam concentrates. As longas an approved class A foamconcentrate is used and the system willbe used within 10-12 weeks no flushingwill be required. When class B foamconcentrate is used flush system thenswitch to class A as most responses areusually class A types.

The following procedures shall be used toflush the foam pump. Refer to figure 4-10for ADT or MDT ΙΙ operating positions andrefer to figure 4-11 for MST operation:

1. Energize apparatus and establish waterflow through a foam capabledischarge. Set fire pump for a lowdischarge pressure, 50 to 75 PSI (3.4 to5.2 BAR).

2. Energize Hale FoamLogix by depressingthe red ON button allowing foamsolution to discharge.

NOTE: When the Hale ADT, MDT ΙΙ or MSTis in the FLUSH position the HaleFoamLogix foam injection system willonly run for 20 seconds.

3. Place the Hale ADT, MDT ΙΙ or MST to theFLUSH position.

4. Observe discharge hose and allow HaleFoamLogix and discharge to run forseveral seconds.

5. After several seconds place the HaleADT or MDT ΙΙ to the TANK A position andallow Hale FoamLogix to run until foamsolution is discharged through the foamcapable hose line.

NOTE: When the Hale MST is used forClass B foam concentrates DO NOTallow the foam pump to run in the FOAMTANK position after flushing foam pump.

6. Place the Hale MST to the FOAM TANKposition and allow Hale FoamLogix torun until Class A foam solution isdischarged through the foam capablehose line. If Class B foam concentrate isused shut down Hale FoamLogiximmediately after switching to FOAMTANK position.

7. Shut down Hale FoamLogix allowingfoam capable discharge to run to flushout the fire pump discharge manifold asrequired. Once clear water flows, closefoam capable discharge and shut downapparatus.

Figure 4-11. Hale MST Operation

SELECTORHANDLE

FLUSHPOSITION

FOAM TANKPOSITION POSITION

INDICATORNAMEPLATE

SELECTOR HANDLE IN FOAM TANK POSITION

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PRIMING THE FOAM PUMP WHEN FOAMTANK HAS RUN DRY

In some instances the foam tank may rundry while operating the Hale FoamLogixsystem. The foam pump is designed topump liquid. When the fire pump is runningthe foam pump may not pump efficientlyagainst 100 to 150 PSI (7 to 10 BAR) backpressure. To reestablish foam concentrateflow quickly the following procedure can beused.

1. Turn the bypass valve to the BYPASSposition.2. With the fire pump flowing waterfrom foam discharge and the HaleFoamLogix on observe the hose from thebypass valve.3. When foam concentrate flows fromthe hose turn the bypass valve back tothe INJECT position. The pump is nowprimed and ready for normal operation.

8. Perform required maintenance checkson the Hale FoamLogix and apparatusto return the apparatus to readycondition.

IMPORTANT: Make sure the Hale ADT orMDT ΙΙ is in the TANK A position and theHale MST is in the FOAM TANK positionwhen apparatus is placed in readycondition.

OPERATION WITH REMOTE ON/OFFSWITCH

The remote ON/OFF switch is used toactivate the Hale FoamLogix system fromthe driver compartment or a location otherthan the control unit. The switch will onlyactivate and deactivate the HaleFoamLogix system, it does not permitadjustment of the injection rate. Use theremote ON/OFF switch as follows:

1. Press the switch down and release toactivate. The LED will light indicating theHale FoamLogix is in the standbyposition.2. When the foam capable dischargenozzle is opened the LED will blinkindicating foam concentrate is beinginjected. When the nozzle is closed theLED will stop flashing.3. Pressing the switch again willdeactivate the Hale FoamLogix systemand the LED will go out.

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MAINTENANCEMAINTENANCE PROCEDURES1. After each use: Flush Hale FoamLogix

foam pump if Class B foam concentratewas used and return to Class A.

2. After each use: Inspect wiring, hoses,flowsensors, and connections fortightness, corrosion, leaks and/ordamage. Refer to installation drawings.

3. After each use: Remove and clean thefoam strainer screen(s). Flush asrequired.

4. Monthly: Verify water flow calibration.5. Monthly: Verify foam feedback

calibration.

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TROUBLESHOOTINGUSER DIAGNOSTICSPower indicator lamps are provided on thedistribution box and on the feedbacksensor. The lamp on the distribution boxlocated next to the ON/OFF switch isilluminated whenever power is supplied tothe control cable. The LED on thefeedback sensor will flash when the sensor isreceiving pulses from the flowsensor. TheseLEDs help to ease tracing of power supplyfaults and eliminates some of the guessworkin troubleshooting. This feature isreferenced in the troubleshooting guide.

If the system malfunctions make sure ALLthe following conditions are met:

� All hose connections correct and tight(Refer to appropriate system plumbingdiagram in Section ΙΙ).

� All electrical connections correct andtight (Refer to appropriate systemelectrical diagram in Section ΙΙ).

� Apparatus electrical system energizedwith power supplied to pump panel andHale FoamLogix.

� Hale FoamLogix power switch locatedon the distribution box is in the ONposition.

� Power indicator LED on the distributionbox is illuminated.

Once all the above conditions are metproceed to the system troubleshootingsection to determine cause of malfunction.

Figure 4-12. Power Indicator LED Location

DISTRIBUTION BOX TOP VIEW

POWERLED

ON/OFFTOGGLESWITCH

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Hale FoamLogix systems consist of individual subsystems working together to providefinished foam solution at the proper percentage.

The entire system is designed using modular components making troubleshooting andrepair easier. Each subsystem has its own set of troubleshooting procedures. Theprocedures that follow will provide a logical flow path to isolate and correct any systemfailure.

NOTE: Hale FoamLogix system electronic components have no user serviceablecomponents and are replaced as a unit. Opening of Hale FoamLogix electroniccomponents will void the manufacturer warranty.

PROBLEM ISOLATION

The first step in troubleshooting the Hale FoamLogix system is to determine whichsubsystem caused the overall system failure. To make this determination operate theapparatus and Hale FoamLogix system in accordance with standard operatingprocedures noting where problems occur.

Refer to the following to isolate the cause of Hale FoamLogix system failure.

Following are the basic steps to follow to isolate system problems. They are presented inblock format in chart 4-1.

1. Setup apparatus for normal operation.2. Power-up apparatus and energize the pump operator panel. Take notice of the Hale

FoamLogix Control unit. If the display is NOT illuminated proceed to the power supplytroubleshooting chart 4-2.

3. If the Hale FoamLogix control unit is illuminated engage apparatus water pump andestablish discharge. If water flow CANNOT be established, troubleshoot the waterpump system in accordance with pump troubleshooting procedures.

4. If there is no indication of water flow on control unit display troubleshoot flowsensorusing procedures outlined in chart 4-3.

5. If water flow can be established turn Hale FoamLogix system ON to flow foam.Observe foam pump discharge, if foam is NOT flowing refer to foam pumptroubleshooting chart 4-4.

6. Check accuracy of system using calibration procedures in Section �� of this manualmaking adjustments as required.

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Chart 4-1. Hale FoamLogix System Troubleshooting

START

ENERGIZE THE APPARATUS FOR NORMAL OPERATIONAND SUPPLY POWER TO PUMP OPERATOR PANEL

PROCEED TOPOWER SUPPLY

TROUBLESHOOTINGCHART 4-2

ENERGIZE FOAMLOGIX SYSTEM ANDESTABLISH FOAM FLOW. REFER TOSECTION III FOR USER CALIBRATION

PROCEDURES TO CHECK FOAM FLOW

IS FOAMLOGIX CONTROLUNIT ILLUMINATED?

FOR ADDITIONAL ASSISTANCECONTACT NEAREST HALE

SERVICE CENTER

YES

NO

REFER TOAPPARATUSOPERATING

PROCEDURES

ENGAGE APPARATUS WATERPUMP AND ESTABLISH WATERFLOW. IS WATER FLOWING?

YES

NO

PROCEED TO HPFFLOWSENSOR


DOES WATER FLOW RATESHOW ON CONTROL UNIT?

YES

NO

PROCEED TOFOAM PUMP


IS FOAM PUMP FLOWINGFOAM CONCENTRATE?

YES

NO

PROCEED TOFOAM PUMP USER

CALIBRATION INSECTION III

IS FOAM PUMP FLOWINGPROPER AMOUNT OF FOAM

CONCENTRATE?

YES

NO

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Chart 4-2. Power System Troubleshooting

START

CONTROL UNITILLUMINATED?

IS POWER INDICATORLED ON DISTRIBUTION

BOX ON?

IS POWER ISOLATIONSWITCH ON?

PROCEED TO CHART4-1 SYSTEM

TROUBLESHOOTING.

TURN SWITCH TO OFF FOR 30SECONDS TO RESET CIRCUITBREAKER. TURN SWITCH ON

TURN SWITCH ONIS POWER INDICATOR LED

ON DISTRIBUTION BOX ON?

ENERGIZE APPARATUSELECTRICAL SYSTEM OR

REPAIR POWER FAULT

IS THERE POWER AT THEPOWER CONNECTION

TERMINAL?

DISCONNECT CONTROL CABLESAND ACCESSORY LEADS FROM

DISTRIBUTION BOX

TURN SWITCH TO OFF FOR 30SECONDS TO RESET CIRCUITBREAKER. TURN SWITCH ON

IS POWER INDICATORLED ON DISTRIBUTION

BOX ON?

REPLACEDISTRIBUTION BOX

RECONNECT CABLES ONE AT ATIME UNTIL LIGHT GOES OUT.REPLACE COMPONENT THAT

CAUSED FAILURE

NO

YES

YES

YES

NO

NO

NO

NO

NO

YES

YES

YES

CHECK CONTROL CABLEINTEGRITY AND REPLACE CABLE

IF NECESSARY

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Chart 4-3. HPF Flowsensor Troubleshooting

START

IS WATERFLOWING?

IS CONTROL UNITDISPLAY LIGHTED?

IS FLOW LED ONCONTROL UNIT

LIGHTED?

DOES WATER FLOWRATE SHOW ONCONTROL UNIT?

DOES WATER FLOWRATE SHOW

ACCURATELY ONCONTROL UNIT?

ESTABLISH WATER FLOWIN ACCORDANCE WITH

APPARATUS OPERATINGPROCEDURES

PROCEED TOPOWER SUPPLY


PRESS SELECTDISPLAY BUTTONUNTIL FLOW LED

LIGHTS

SHUTDOWN WATERFLOW AND REMOVE

FLOWSENSORFROM TEE

SEE USERCALIBRATION

PROCEDURES INSECTION III AND

CALIBRATEFLOWSENSOR?

CONTINUE SYSTEMTROUBLESHOOTING

USING CHART 4-1

IS FLOWSENSORPADDLEWHEEL

JAMMED?

CANPADDLEWHEEL

BE FREED?

REPLACEFLOWSENSOR

SPINPADDLEWHEEL

BY HAND

DOES WATERFLOW RATESHOW ON

CONTROL UNIT?

DISCONNECT FLOWSENSORCABLE AND CONNECT A NEW

CABLE TO CONTROL UNIT.SPIN PADDLEWHEEL

DOES WATER FLOWRATE SHOW ONCONTROL UNIT?

REPLACEFLOWSENSOR

SECURE NEWFLOWSENSOR

CORDSET

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

YES NO

YESNO

NO

YES

NO

YES

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Chart 4-4. Foam Pump Troubleshooting

START

IS FOAMCONCENTRATE

FLOWING?

IS CONTROL UNITDISPLAY

ILLUMINATED?

IS WATERFLOWING?

IS CONTROL UNITON LED

ILLUMINATED?

IS FOAM PUMPMOTOR

OPERATING?

PROCEED WITHNORMAL OPERATION

ESTABLISH WATER FLOWIN ACCORDANCE WITH

APPARATUS OPERATINGPROCEDURE

PROCEED TO POWERSUPPLY


DEPRESSCONTROL UNIT

ON BUTTON

FOR ADDITIONALASSISTANCE CONTACT

NEAREST HALE SERVICECENTER

CONTROL UNITBARGRAPH INDICATES

FOAM FLOW?

FOR ADDITIONALASSISTANCE CONTACT

NEAREST HALE SERVICECENTER

IS FEEDBACKSENSOR LED

LIGHTED?

NO

YES

NO

YES

NO

YES

NO NO

YES

YES YES

NO

NO NO

IS CONTROL UNITON LED

ILLUMINATED?

YES

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PARTS IDENTIFICATIONFOAM PUMP ASSEMBLY

REF PART NUMBER DESCRIPTION QTY UNIT501-3120-15-0 (MODEL 3.3) FM 3.3 PUMP ASSY (12 VOLT DC MOTOR)501-3120-24-0 (MODEL 3.3) FM 3.3 PUMP ASSY (24 VOLT DC MOTOR)501-3130-15-0 (MODEL 5.0) FM 5.0 PUMP ASSY (12 VOLT DC MOTOR)501-3130-24-0 (MODEL 5.0) FM 5.0 PUMP ASSY (24 VOLT DC MOTOR)

1 501-3110-00-0 FM3.0 GEAR PUMP ASSY (FM 3.0, FM 3.3) 1 EA501-3130-00-0 FM5.0 GEAR PUMP ASSY (FM5.0) 1 EA

2 013-0740-00-0 TERMINAL BOOT (BLACK) 1 EA3 013-0740-05-0 TERMINAL BOOT (RED) 1 EA4 200-2700-00-0 CABLE ADAPTER ASSEMBLY 1 EA5 017-0680-00-0 DRIVE KEY 1 EA6 018-1406-02-0 SCREW 5/16-18 X 3/4 PLD 4 EA7 018-1612-17-0 SCREW-3/8-16 X 1-1/4 4 EA8 045-0770-00-0 ELECTRIC MOTOR (12 VDC) 1 EA

045-0770-01-0 ELECTRIC MOTOR (24 VDC) 1 EA9 097-0140-02-0 WASHER-3/8 300 SER STNLS LOCK 4 EA10 097-0310-00-0 WASHER-1/4 EXT TOOTH TYPE “A” 4 EA11 097-0560-02-0 WASHER-5/16 300 SER SST LOCK 4 EA12 097-0810-01-0 WASHER-5/16 ZINC PL STL FLAT 4 EA13 097-1971-00-0 5 MM SEAL WASHER 1 EA14 110-1200-02-0 NUT-1/4-20 ZINC PLATED STEEL 4 EA15 NUT-5 MM X 0.5 PITCH SST (INCLUDED WITH ITEM 16) 1 EA16 200-2481-00-0 SPEED SENSOR- 5MM (POWERED) 1 EA17 200-2501-00-0 DISTRIBUTION BOX (FM 5.0, FM 3.3) 1 EA

200-2501-01-0 DISTRIBUTION BOX (FM 3.0) 1 EA18 538-1620-00-0 RELIEF VALVE KIT19 018-9610-00-0 ADJUSTING SCREW 1 EA20 042-0680-00-0 RELIEF VALVE SPRING 1 EA21 073-0220-00-0 RELIEF VALVE PISTON 1 EA22 097-1980-00-0 SEALING WASHER 2 EA23 110-2701-06-0 NUT-3/4-16 300 SER SST JAM 1 EA24 110-2703-06-0 NUT-3/4-16 300 SER STNLS ACORN 1 EA25 513-0350-00-0 BRACKET ASSEMBLY 1 EA26 013-2050-00-0 GROUND STRAP ASSY 1 EA27 097-2110-00-0 FLAT WASHER- 3/8 BRASS 4 EA28 110-1600-08-0 NUT-3/8-16 UNC BRASS 2 EA29 546-1780-00-0 CONNECTOR KIT (NOT SHOWN) 1 EA30 013-2020-05-0 FOAMLOGIX 6-PIN CABLE ASSY 16.41 FT(5 M) LG 1 EA

013-2020-01-0 FOAMLOGIX 6-PIN CABLE ASSY 3.28 FT (1 M) LG 1 EA013-2020-02-0 FOAMLOGIX 6-PIN CABLE ASSY 6.56 FT (2 M) LG 1 EA013-2020-04-0 FOAMLOGIX 6-PIN CABLE ASSY 13.12 FT (4 M) LG 1 EA013-2020-06-0 FOAMLOGIX 6-PIN CABLE ASSY 19.69 FT (6 M) LG 1 EA

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1 038-1790-00-0 CHECK VALVE INJECTOR 1 EA2 101-1630-12-0 FOAM SYSTEM DIAGRAM NAMEPLATE (SINGLE TANK) 1 EA3 107064 CONTROL UNIT 1 EA4 110-1703-06-0 NUT 1 EA5 012-1440-00-0 TEE HANDLE 1 EA6 012-0450-00-0 HANDLE COVER 2 EA7 018-1003-43-0 SCREW #10-24 X 3/8 IN LG 2 EA8 101-1630-01-0 BYPASS PLACARD 1 EA9 038-1810-00-0 BYPASS VALVE 1 EA10 082-0408-02-0 1/2 INCH NPT CLOSE NIPPLE (BRASS) 1 EA

ADDITIONAL FOAMLOGIX SYSTEM COMPONENTSREF PART NUMBER DESCRIPTION QTY UNIT

1

4

3 2

5

6

8

9

10

7

6

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FOAMLOGIX FLOWSENSOR

1 102714 PADDLE WHEEL2 4842010 SADDLE CLAMP (2 INCH)

4843010 SADDLE CLAMP (2-1/2 INCH)4844010 SADDLE CLAMP (3 INCH)4846010 SADDLE CLAMP (4 INCH)4845010 SADDLE CLAMP (5 INCH)

3 082-3060-00-0 WELD FITTING (STAINLESS STEEL)309020 WELD FITTING (STEEL)309010 WELD FITTING (ALUMINIUM)

4 107400 FOAMLOGIX FLOWSENSOR CABLE 10 FT (3 M) LG 1 EA107362 FOAMLOGIX FLOWSENSOR CABLE 20 FT (6 M) LG 1 EA107401 FOAMLOGIX FLOWSENSOR CABLE 30 FT (9 M) LG 1 EA

5 108751 DUAL CHECK VALVE MANIFOLD ASSEMBLY 1 EA108893 SINGLE CHECK VALVE MANIFOLD ASSEMBLY 1 EA

6 513-0270-04-0 WIRE HARNESS 1 EA

REF PART NUMBER DESCRIPTION QTY UNIT

3

2

1

2

4

5 5

DUAL CHECK VALVE MANIFOLDSINGLE CHECK VALVE

MANIFOLD

6

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HALE FOAMLOGIX AIR DUAL TANK VALVE (ADT)

538-1640-00-0 ADT VALVE ASSEMBLY (INCLUDES ITEMS MARKED * BELOW)

*1 010-0660-00-0 INLET LINE STRAINER 1 EA

*2 012-1430-00-0 "PULL TO BYPASS" KNOB 1 EA3 018-1222-12-0 SCREW ¼-20 X 2-¼ IN LG 1 EA*4 018-1410-24-0 SCREW 5/16-18 X 1 IN LG 4 EA5 038-1800-00-0 TOGGLE VALVE 1 EA6 040-1180-00-0 40-3N118 SEAL RING 1 EA7 040-1230-00-0 O-RING 123 BUNA 1 EA8 082-0142-02-0 FITTING 1/8 NPT X ¼ TUBE PUSH CONN 2 EA9 082-0143-02-0 ELBOW 1/8 NPT X ¼ TUBE PUSH CONN 2 EA*10 082-0408-02-0 ½ INCH NPT CLOSE NIPPLE (BRASS) 1 EA

*11 082-0414-02-0 ½ INCH NPT SERVICE ELBOW (BRASS) 1 EA

*12 082-0521-05-0 ¾ NPT X ¾ INCH HOSE NYLON ELBOW (NOT SHOWN) 1 EA

*13 082-0545-05-0 ¾ NPT X 1 INCH HOSE NYLON ELBOW (NOT SHOWN) 1 EA14 159-0760-00-0 SPACER 1 EA15 200-0540-00-0 LIGHT ASSEMBLY (GREEN) 1 EA16 200-0540-10-0 LIGHT ASSEMBLY (RED) 1 EA17 200-1280-00-0 A-B INTERLOCK ASSEMBLY 1 EA*18 200-2450-00-0 SWITCH 2 EA19 101-1630-00-0 ADT NAMEPLATE 1 EA20 101-1630-07-0 FOAM SYSTEM DIAGRAM NAMEPLATE

(DUAL TANK) 1 EA21 513-0300-00-0 ADT WIRING HARNESS 1 EA22 538-1610-00-0 ADT SELECTOR PANEL ASSEMBLY 1 EA23 538-1640-01-0 ADT VALVE ASSEMBLY 1 EA24 507-0380-00-0 AIR HARNESS ASSEMBLY (OPTIONAL) 1 EA

REF PART NUMBER DESCRIPTION QTY UNIT

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1

10

9

18

15

2

20

17

4

5

8

16

19

11

12

13

21

3

14 6

7

24

23

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WARRANTYLIMITED WARRANTY

EXPRESS WARRANTY. Hale Products Inc. (“Hale”) hereby warrants to the original buyer thatproducts manufactured by it are free of defects in material and workmanship for one (1)year. The “Warranty Period” commences on the date the original buyer takes delivery ofthe product from the manufacturer.

LIMITATIONS. HALE’S obligation is expressly conditioned on the Product being.— Subjected to nominal use and service;— Properly maintained in accordance with HALE’s Instruction Manual as to

recommended services and procedures;— Not damaged due to abuse, misuse, negligence or accidental causes;— Not altered, modified, serviced (non-routine) or repaired other than by an

Authorized Service Facility;— Manufactured per design and specifications submitted by the original Buyer.

THE ABOVE EXPRESS LIMITED WARRANTY IS EXCLUSIVE. NO OTHER EXPRESS WARRANTIES AREMADE. SPECIFICALLY EXCLUDED ARE ANY IMPLIED WARRANTIES, INCLUDING WITHOUTLIMITATIONS, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE OR USE; QUALITY; COURSE OF DEALING; USAGE OF TRADE; OR PATENTINFRINGEMENT FOR A PRODUCT MANUFACTURED TO ORIGINAL BUYER’S DESIGN ANDSPECIFICATIONS.

EXCLUSIVE REMEDIES. If Buyer promptly notifies HALE upon discovery of any such defect(within the Warranty Period), the following terms shall apply:

— Any notice to HALE must be in writing, identifying the Product (or component)claimed defective and circumstances surrounding its failure;

— HALE reserves the right to physically inspect the Product and require Buyer to returnsame to HALE’S plant or other Authorized Service Facility;

— In such event, Buyer must notify HALE for a Returned Goods Authorization numberand Buyer must return the Product F.O.B. within (30) days thereof;

— If determined defective, HALE shall, at its option, repair or replace the Product, orrefund the purchase price (less allowance for depreciation),

— Absent proper notice within the Warranty Period, HALE shall have no further liabilityor obligation to Buyer therefore.

THE REMEDIES PROVIDED ARE THE SOLE AND EXCLUSIVE REMEDIES AVAILABLE. IN NO EVENTSHALL HALE BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING,WITHOUT LIMITATION, LOSS OF LIFE; PERSONAL INJURY; DAMAGE TO REAL OR PERSONALPROPERTY DUE TO WATER OR FIRE; TRADE OR OTHER COMMERCIAL LOSSES ARISING,DIRECTLY OR INDIRECTLY, OUT OF PRODUCT FAILURE.

6/26/2003 foamlogix - montgomery county, md...to small leads that are supplying some other device...

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