FoamPRO 3012 User manual

Unit

Serial

Number

System 3012

Model 3012

INSTALLATION AND

OPERATION MANUAL

Form 836

6/19

All quality FoamPro products are ruggedly designed, accurately machined, carefully assembled, thoroughly inspected

and tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it is important to follow

the instructions on care and operation. Proper use and good preventive maintenance will lengthen the life of your unit.

ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE.

FoamPro • 26 Southern Blvd. • Nesconset, NY 11767 USA • 800-533-9511 • FAX 816-892-3178

Installation and Operation Manual

TABLE OF CONTENTS

SECTION PAGE

1 SAFETY ............................................................................................................................ 3

2 A QUICK LOOK AT HOW THE SYSTEM WORKS .......................................................... 5

3 SYSTEM COMPONENT DESCRIPTION ......................................................................... 7

4 INSTALLER SUPPLIED PARTS....................................................................................... 9

5 INSTALLATION PLANNING ............................................................................................ 12

6 FOAM PUMP AND HYDRAULIC CONTROL VALVE INSTALLATION ........................... 13

7 HYDRAULIC PLUMBING INSTALLATION...................................................................... 14

8 WATER AND FOAM PLUMBING COMPONENT INSTALLATION ................................. 16

9 ELECTRICAL EQUIPMENT INSTALLATION.................................................................. 21

10 MAKE SURE EVERYTHING IS WORKING RIGHT ........................................................ 27

11 CALIBRATION AND SETUP ........................................................................................... 30

12 OPERATING INSTRUCTIONS........................................................................................ 33

13 MAINTENANCE............................................................................................................... 40

14 TROUBLESHOOTING..................................................................................................... 41

15 SPECIFICATIONS ........................................................................................................... 46

16 WARRANTY ......................................................................................................Back Cover

NOTE TO SYSTEM INSTALLERS

IMPORTANT: Please provide a copy of the FoamPro manual to the end user of the equipment.

For additional FoamPro manuals, contact by FAX 816-892-3178, web site www.foampro.com,

or call 800-533-9511. Request Form No. 836.

Installation and Operation Manual

System 3012

The following special notices are used to notify and

advise the user of this product of procedures that may be

dangerous to the user or result in damage to the product.

NOTE: Notes are used to notify of installation,

operation, or maintenance information that is

important but not safety related.

CAUTION: Caution is used to indicate the presence

of a hazard, which will or can cause minor injury or

property damage if the notice is ignored.

WARNING: Warning denotes that a potential

hazard exists and indicates procedures that must

be followed exactly to either eliminate or reduce

the hazard, and to avoid serious personal injury, or

prevent future safety problems with the product.

DANGER: Danger is used to indicate the presence

of a hazard that will result in severe personal injury,

death, or property damage if the notice is ignored.

• Do not pump at pressures higher than the maximum

recommended pressure. [400 PSI (28 bar)]

• Do not permanently remove or alter any guarding

devices or attempt to operate the system when those

guards are temporarily removed.

• Always disconnect the power source before

attempting to service any part of the pump.

• Release all pressure within the system before

servicing any of its component parts.

• Drain all concentrate and water from the discharge

system before servicing any of its component parts.

• Check all hoses for weak or worn conditions after

each use. Ensure that all connections and fittings are

tight and secure.

• Use only pipe, hose, and fittings from the foam pump

outlet to the injection point, which are rated at or

above 400 psi (28 BAR) minimum rating, at which the

water pump system operates.

• Use only pipe, hose, and fittings from the hydraulic

oil pump to the foam pump hydraulic motor, which

are rated at 3000 psi (207 BAR) minimum working

pressure or better and are approved for mobile

hydraulic system use.

• Any electrical system has the potential to cause

sparks during service. Take care to eliminate

explosive or hazardous environments during service/

repair.

• Rotating drive line components can cause injury. Be

careful of rotating components when adjusting load

sense pump compensator.

• Slowly loosen the foam pressure line fittings and

allow the pressure to escape. Protect face and eyes

from any potential spray which may occur.

CAUTION: Do not attempt to operate the system at or

above a temperature of 160°F (71°C).

WARNING: Ensure that the electrical source of power

for the unit is a 12 or 24 Volt, negative ground DC

system. Power and ground lines must come directly

from the battery without any connections to other high

power devices, such as primer pumps, hose reels,

light bars, etc. Power required for the valve driver box

on the hydraulic motor-driven foam pump must have a

minimum current rating of at least 5 AMPS.

CAUTION: Periodically inspect the pump and the

system components. Perform routine preventive

maintenance as required. Failure to perform routine

maintenance may cause damage to the system.

See the maintenance section of this manual for

recommended maintenance procedures and intervals

between maintenance work.

NOTE: Read and understand these installation

instructions before proceeding with the equipment

installation.

CAUTION: Use only approved petroleum-base

hydraulic fluids meeting the specifications as noted

in Section 4. Never mix fluid types. Ensure all hoses

and seals are compatible with fluids used. Do not use

water or glycol-based fluids. Do not use phosphate

ester-type fluids.

1 Safety Before attempting to install a FoamPro System 3012, read all

of the following safety precautions and follow carefully.

Installation and Operation Manual

CAUTION: Dirt and contaminant’s are the primary

causes of premature wear and failure in any hydraulic

system. Use extreme care during assembly and

service to keep contaminant’s out of the system.

WARNING: Always disconnect the ground straps,

electrical wires and control cables from the Digital

Display Control Module and all other FoamPro

equipment before electric arc welding at any point on

the apparatus. Failure to do so will result in a power

surge through the unit that could cause irreparable

damage.

CAUTION: All DOT, SAE or other applicable

standards must be followed when installing

the hydraulic supply system. Pay close attention

to engine and transmission manufacturer drive

limitations.

CAUTION: Never attempt to cut or lengthen the

molded cables. Doing so will result in RFI/EMI

interference. Contact the factory if molded cables of

a different length are required.

CAUTION: To ensure the integrity of fitting

connections in the hydraulic system, use only SAE

JIC 37° flare or equal type hose connections.

CAUTION: To prevent damage to the hydraulic motor

seal, the motor case drain must have its own 1/4 inch

(6.3 mm) inside diameter hose installed to return

hydraulic oil to the reservoir.

WARNING: The load sense pump compensator is

preset at the factory for proper operation. DO NOT

adjust the load sense compensator.

CAUTION: The cables shipped with each FoamPro

3012 are tested at the factory with that unit. Improper

handling and forcing connections can damage these

cables which could result in other system damage.

CAUTION: The foam tank low-level sensor must be

utilized to protect the foam pump from dry running.

Failure to do so will void warranty.

CAUTION: The input power wire is not protected by

the system circuit breaker. Be careful not to damage

or short circuit this wire.

CAUTION: When pouring foam concentrate directly

into the foam pump, the inlet strainer is bypassed.

Make sure contaminant’s are not poured into pump

chamber. Premature pump wear or damage may

result if contaminant’s are allowed to enter pump

chamber.

CAUTION: Do not run the FoamPro 3012 for more

than one minute deadheaded against the pressure

gauge, as the foam pump could be damaged.

CAUTION: When operating the FoamPro in the

“Simulated Mode” function, an outlet for the foam

concentrate must be provided. Otherwise dangerous

excessive pressure may be built up in the apparatus

water piping and/or hoses. This outlet for the foam

concentrate can be provided by turning the “CAL/

INJECT” valve to the “CAL” position. A suitable

container must be provided to collect the foam

concentrate.

CAUTION: Do not mount electronics where they will

be exposed to direct water spray.

Installation and Operation Manual

System 3012

2 A Quick Look at How the System Works

The FoamPro 3012 system is an electronic and

hydraulic foam concentrate proportioning system

designed to provide the wide range of foam concentrate

injection rates necessary for both Class A and Class B

foam operations.

The FoamPro system will accurately deliver from 0.1%

to 10.0%, or from 0.1 to 12.0 gpm of foam concentrate

to the foam injection point. The maximum rated

concentrate flow rates obtainable are shown in the

system specifications in Section 15.

The FoamPro 3012 system is a flow-based

proportioning system that measures water flow and

then injects the correct proportional amount of foam

concentrate to maintain the desired percentage.

The basic FoamPro system is shown in Figure 2-1.

The flowmeter measures the water flow and sends

a signal to the Digital Display Control Module. A

speed-sensing device monitors the foam pump output.

Constant comparison of these two information signals

by the controller ensures maintenance of the desired

proportion of foam concentrate at all times based on

water flow rate, independent of any variations in fire

pump intake or discharge pressures. As water flow

increases or decreases, the foam concentrate rate

of injection is increased or decreased automatically

to correspond to water flow, maintaining the proper

concentrate percentage as selected on the Digital

Display Control Module.

CAUTION: If the power to the FoamPro unit fails or

is shut off during operation, the system will remain

in operation at the last setting. DO NOT close the

discharge to the system until the hydraulics are

disengaged. To turn the system off, it is required to

disengage the hydraulic drive PTO.

Foam concentrate is injected directly into the water

stream on the discharge side of the water pump. It is

then fed as foam solution into a standard fog nozzle,

an air-aspirated nozzle, a straight bore nozzle, or into

a CAFS system, by the main fire pump. Since the foam

is injected on the discharge side of the fire pump and

check valves are used at installation, contamination of

the booster tank, fire pump, and relief valve with foam

concentrate is eliminated.

Hydraulic power to operate the foam pump is to be

provided by a separate hydraulic pump driven by the

apparatus system.

Electrical power to operate the foam systems is

provided by the apparatus electrical system.

Order optional system components listed in Section 3

to accommodate system design and requirements. The

components listed have been tested with the FoamPro

systems and provide for optimum system performance.

FoamPro Model 3012 systems will pump Class A

and Class B (Aqueous Film Forming Foam, AFFF,

and Alcohol-Resistant Aqueous Film Forming Foam,

AR-AFFF) to capacity. Many brands of AR-AFFF

exhibit higher viscosity characteristics due to chemical

composition and polymers. As viscosity increases,

diminished flow may affect pump performance. Because

of numerous variables; including pump design, foam

cell configuration, inlet piping/components and system

layout; please contact FoamPro at 800-533-9511 for

application-specific recommendations when foam

viscosities of 2000 cps (Brookfield #3 spindle @ 30 rpm)

or higher are used.

Installation and Operation Manual

Figure 2-1 FoamPro 3012 System Layout

Foam Tank

Water Tank

Water Pump

Power & Ground

Connection Pin

A (Red) + 12 VDC

to + 27 VDC Pin B

(Black) Ground

Water Flowmeter

Line Strainer

Foam Pump Assy. Speed Sensor

Check Valve

(Optional)

Main Waterway

Check Valve

Flush Water

Shutoff Valve

Foam Tank

Shutoff Valve

Outboard

Pickup

Foam Injection Point

Single Discharge

Calibrate/Inject Valve

Foam Injection Check Valve

Hydraulic Motor

and Control Valve

Hydraulic Valve

Control Driver

Foam Tank

Low-Level

Sensor

Digital Display Controller

Multiple Discharge

with Manifold

Installation and Operation Manual

System 3012

3 System Component Description

The following components are packaged with the

standard FoamPro 3012 system:

1. Digital Display Control Module

2. Molded Cables

3. Foam Pump and Hydraulic Control Valve Assembly

4. Instruction Placard

5. Low-Level Sensor (One required. Not packaged

with the unit. Order separately.)

6. Calibrate/Inject Valve

7. Inlet Line Strainer

8. Check Valve 1/2"’ NPT Foam Injection. This NFPA

1906 (draft) required check valve prevents water

back flowing into foam system.

9. RFI/EMI Suppression Beads

10. FoamPro Paddlewheel Flowmeter or Manifold

(The flowmeter is a required component. The

size is specified and ordered under a separate

part number when the FoamPro is ordered. The

flowmeters are available with 1-1/2", 2", 2-1/2", 3",

and 4" NPT threads; or manifolds with Victaulic-

grooved ends in 1-1/2", 2", 2-1/2", 3” and 4" pipe

sizes. All flowmeters have grooved victaulic ends.

Insert-style flowmeters are available for larger pipe

diameters. Part numbers for the various flowmeters

can be found in Section 15. Up to 4 flowmeter

sensors can be used with the FoamPro System

when a MultiFlo interface is used.)

11. Hydraulic Load-Sensing Pump

Installation and Operation Manual

SYSTEM ACCESSORIES AVAILABLE

FoamPro MultiFlo Interface

Combines 2 to 4 flowmeters

for single point systems

System Placard Solid State Contactor

P/N 2510-0043

Nesconset, NY 11767US

Main Waterway Check Valve with Drain Port

Available in stainless steel.

NPT threaded ends with injection and drain ports

System

Specification Placards

Remote Start/Stop

Polypropylene Foam Tank(s)

8, 12 or 20 gallon capacity

Foam Manifold

All stainless steel with main waterway

check valve, water flowmeter, injection

port, and drain port. Victaulic grooved ends

For more information on these accessories, please see publications 856 and PL-21.

Electronic Concentrate

Management System

Electronic control for Dual Tank Systems

with interface to controller

Electronic Concentrate Management System

Electronic control of single or dual tank onboard

systems and an off-board pickup.

2002 Series and larger only

Main Waterway Check Valve

All stainless steel with Victaulic

ends and injection and drain ports

NFPA Calibration and Test Kit

For use with 1600 thru 3012 systems

Dual Injection Management System

Provides capability for switching between

two injection points

Single Tank Flush Kits

Both Internal and External flushing kits

Installation and Operation Manual

System 3012

4 Installer Supplied Parts

FoamPro 3012 systems are provided with major

components and accessories required for installation. Due

to differences in chassis and apparatus configurations,

the installer must provide hydraulic coolers, fluids,

reservoir, pipe, hoses, tubing, wire and fittings to satisfy

installation requirements. The following paragraphs list the

specifications for selection of these components. Before

beginning system installation, read this section thoroughly

to make sure the proper components are selected. For

detailed system installation instructions, refer to Sections 5,

6, 7, 8 and 9.

CAUTION: All DOT, SAE or other applicable standards

must be followed when installing the hydraulic system.

Pay close attention to engine and transmission

manufacturer drive limitations.

Hydraulic Pump Drive Selection

The foam pump for the FoamPro 3012 system is powered

by hydraulics. Power for the system comes from hydraulic

oil supplied by a hydraulic pump attached to the apparatus

engine. To obtain optimum performance from the hydraulic

motor-driven foam pump, FoamPro has designed the 3012

system to use a load-sensing, pressure-compensated

hydraulic pump. The FoamPro load-sensing hydraulic

pump provides proper hydraulic fluid flow with reduced heat

load, torque and horsepower requirements.

The FoamPro load-sensing hydraulic supply pump will

provide the correct fluid flow over the widest range of engine

speeds. See system specifications for the maximum required

pump speed to attain maximum performance levels. By

using a PTO ratio greater than 1.0, the minimum engine

speed for full system performance could be idle speed.

A transmission PTO should be used to drive the hydraulic

supply pump. Transmission PTOs have greater torque

capabilities and provide adequate power for the hydraulic

pump. Selection of a PTO transmission with a standard

SAE mounting pad will allow bolting the hydraulic pump

directly to the transmission. The FoamPro load-sensing

hydraulic supply pump has a standard 2-bolt SAE “B”

mounting flange and a 13 tooth, 16/32-pitch splined shaft.

Other shaft configurations are available. The shaft rotation

of the pump is clockwise when looking at the pump shaft, or

counterclockwise when facing the rear of the pump. Check

with the FoamPro factory for other configurations that may

be available. See Section 15 for pump dimensions.

Control of the PTO may be provided by a manual shift

lever, shift cable or solenoid. The manual shift-type PTO

may be left in gear all the time to circulate oil as soon as the

engine is started, since the load-sensing hydraulic pump

will draw less than 2 hp when operating in standby mode.

The PTO shift can be labeled “Service Disconnect.”

When selecting a transmission PTO, it is imperative that

consideration be given to frame clearances and the space

in which the hydraulic supply pump is to be mounted. For

new installations, initial design and planning will eliminate

clearance problems. When the FoamPro 3012 system is

being installed as a retrofit, all clearances must be taken

into account. Consult PTO and chassis manufacturers to

determine dimensions and clearances required.

CAUTION: The use of an accessory drive pad is

not recommended since adequate torque usually

is not available to drive the hydraulic supply pump

and accessories.

Choosing the Proper PTO

It is important to turn the hydraulic pump at the proper

speed to ensure that the correct hydraulic pressure is

produced over the full operating range of the foam system.

When selecting a PTO to drive the hydraulic pump,

compare the maximum RPM for the water pump with the

maximum RPM (2,500 RPM) for the hydraulic pump. Then

select a PTO that will provide the best performance at a

lower RPM.

For Example: the maximum speed you can turn the water

pump is 1,800 RPM. For the 3012 system hydraulic pump,

the minimum speed is 1,350 RPM, and the maximum

speed is 2,500 RPM. It is recommended to choose a PTO

with a range of 1 - 1.35 conversion rate (or higher).

Installation and Operation Manual

According to the above example, the following table

shows the Engine Speed with the corresponding Hydraulic

Pump Speed:

Engine Speed Hydraulic Speed

800 RPM 1080 RPM

900 RPM 1215 RPM

1000 RPM 1350 RPM

1100 RPM 1385 RPM

1200 RPM 1620 RPM

1300 RPM 1755 RPM

1400 RPM 1890 RPM

1500 RPM 2025 RPM

1600 RPM 2160 RPM

1700 RPM 2295 RPM

1800 RPM 2430 RPM

Oil Reservoir

A hydraulic reservoir will be required to be installed in the

apparatus. See Section 15 for minimum recommended

reservoir capacity. A larger reservoir may be installed and

is recommended if the apparatus is to run at maximum

capacity for an extended period of time and to allow air to

settle out of the oil.

The reservoir must have a diffuser on the inlet to prevent

entrapment of air into the system. A particle screen on the

oil outlet to the hydraulic pump of 150 mesh (125um) is

recommended to help keep dirt out of the system. A baffle

to separate the inlet and outlet sections should be installed

in the reservoir. A vented, filtered breather of sufficient

size to allow filling of oil is required and an oil drain plug

is recommended.

A sight gauge with thermometer is also recommended for

easy checking of the oil level and to monitor oil temperature.

The oil reservoir should be mounted away from heat

sources, such as exhaust systems, and be in a location that

allows easy access for checking and filling the oil.

The return line from the cooler to the reservoir should have a

replaceable type oil filter with at least a 10 microm absolute

rating and sized to at least a 15 gpm flow rate. Note the larger

the flow rate capacity of the filter, the longer the maintenance

interval can be (minimum replacement is annually).

Oil Cooler

An oil cooler capable of maintaining the temperature of

the hydraulic oil at 140° to 180°F (60° to 82°C) is required.

Use of an air-to-oil radiator-type heat exchanger mounted

in front of the apparatus radiator should provide adequate

cooling for the hydraulic system oil. An electric fan attached

to the oil cooler permits mounting of the oil cooler anywhere

fresh air circulation is available. A thermostat is required to

be included for quick warm up of the oil in cold climates.

Check the system specifications page in Section 15 for

minimum heat load information to properly size the cooler.

Oil to water heat exchangers can be installed, but they

present special problems such as sediment accumulation,

drainage and overheating when running in standby

mode for extended periods without discharging water.

If a hydraulic oil to water heat exchanger is to be used,

proper maintenance, monitoring and pumping procedures

must be followed. The oil to water exchangers must be

installed per the manufacturer’s recommendations and

NFPA requirements.

Hydraulic Oil

Ratings and data for the FoamPro 3012 system are based

on operating with premium hydraulic fluids containing

oxidation, rust and foam inhibitors. These premium fluids

include premium turbine oils, API CD engine oils per

SAE J183, M2C33F or G automatic transmission fluids

(ATF), Dexron (ATF) meeting Allison C-3 or Caterpillar

TO-2 requirements.

The recommended hydraulic fluid operating viscosities

are typically 70 to 278 SUS (12 to 60 cSt) within the

recommended temperature operating range for optimum

performance. The hydraulic oil should have an ISO rating of

between 32 to 68 depending on climatic conditions.

Hydraulic Hoses and Fittings

High pressure hydraulic hoses and fittings are to be rated at

3000 PSI (207 BAR) minimum working pressure. To reduce

the potential for leaks at the hydraulic fittings, use SAE 37°

flare JIC type fittings or SAE straight thread O-ring fittings.

See the table for required fitting sizes, minimum hose

size, and minimum hose pressure ratings for the hydraulic

components in Section 15.

Foam Concentrate Suction Lines

Fittings and hoses from the foam tank to the inlet of

the foam pump must be supplied. Use 1-1/2" (38 mm)

minimum inside diameter or larger clear suction hose

depending on the viscosity of the foam concentrate. Many

Class B foams are more viscous and may require

1-1/2" (38 mm) minimum or larger inside diameter hoses.

Use fittings and components that are rated for 23" Hg

(584.2mm) vacuum and 50 PSI (3 Bar) pressure or better.

The components used must be compatible with the foam

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