System 1600 and 1601
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Form 850 12/20 System 1600 and 1601 INSTALLATION AND OPERATION MANUAL Unit Serial Number 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 .................................................... 4 3 SYSTEM COMPONENT DESCRIPTION ................................................................... 5 4 INSTALLER SUPPLIED PARTS ................................................................................ 7 5 INSTALLATION PLANNING ....................................................................................... 8 6 PLUMBING COMPONENT INSTALLATION ............................................................. 9 7 ELECTRICAL EQUIPMENT INSTALLATION ........................................................... 13 8 MAKING SURE EVERYTHING IS WORKING RIGHT ............................................. 19 9 CALIBRATION AND SETUP ................................................................................... 20 10 OPERATING INSTRUCTIONS ................................................................................. 21 11 OPERATION OPTIONS ........................................................................................... 23 12 MAINTENANCE ........................................................................................................ 25 13 TROUBLESHOOTING .............................................................................................. 26 14 PARTS IDENTIFICATION ........................................................................................ 28 15 CONTROL MODULE TEMPLATE/INSTALLATION DRAWINGS ............................ 31 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. 850. 2 System 1600/1601 Installation and Operation Manual Before attempting to install a FoamPro System 1600 and/or 1601, 1 Safety read all of the following safety precautions and follow carefully. 1. Do not pump at pressures higher than 10. WARNING: Ensure that the electrical source of the maximum recommended pressure power for the unit is a 12 or 24 volt, negative [400 psi (28 BAR)]. ground, DC system. Power and ground lines 2 . Do not permanently remove or alter any guarding must come directly from the battery without devices or attempt to operate the system when any connections to other high power devices, these guards are temporarily removed. such as primer pumps, hose reels, light bars, 3. Always disconnect the power source before scene lighting, etc. Refer to Section 7 for attempting to service any part of the pump. Note, detailed information. this system contains a capacitor which will hold a 11. CAUTION: Ensure that the electrical charge for a time after the power is disconnected. source of power for the unit is the appropriate Take care to dissipate this charge, by connecting a 12 or 24 volt, negative ground DC system, with 12 or 24-volt test lamp from the pump base to the a minimum current rating of at least 32 amps for positive main power terminal. 12 VDC or 16 amps for 24 VDC System 1600’s. 4. Release all pressure within the system before 12. CAUTION: Periodically inspect the pump and servicing any of its components. the system components. Perform routine 5. Drain all concentrate and water from the preventive maintenance as required. Failure discharge system before servicing any of its to perform routine maintenance may cause component parts. damage to the pump. See the maintenance 6. Check all hoses for weak or worn conditions after section of this manual for recommended each use. Ensure that all connections and fittings maintenance procedures and intervals between are tight and secure. maintenance work. 7. Use only pipe, hose, and fittings from the foam 13. CAUTION: Read and understand “Operating pump outlet to the injector fitting, which are rated Instructions” section before attempting to at or above the maximum pressure [400 psi (28 operate the unit. BAR) minimum] rating at which the water pump 14. CAUTION: Always disconnect the ground system operates. straps and control cables from the control 8 . Any electrical system has the potential to cause module or other FoamPro equipment before sparks during service. Take care to eliminate electric arc welding at any point on the explosive or hazardous environments during apparatus. Failure to do so will result in a service/repair. power surge through the unit that could cause 9. CAUTION: Do not attempt to operate the system irreparable damage to the system components. at or above a temperature of 160°F (71°C). 15. CAUTION: The cables shipped with each FoamPro unit are tested at the factory. Improper handling and forcing connections can damage these cables which could result in other system damage. 3 Installation and Operation Manual 2 A Quick Look at How the System Works The FoamPro System 1600/1601 is an electric motor Since foam is injected on the discharge side of the fire driven flow-based proportioning system that measures pump, and check valves are to be used at installation, water flow and then injects the proportional amount of there is no foam concentrate contamination of the foam concentrate to maintain the preset percentage. booster tank, fire pump and relief valve. The basic FoamPro 1600/1601 system is shown in Figure 1. The system will accurately deliver from Order optional system components listed in Section 3 0.1% to 1.0% foam concentrate to the foam injector to accommodate system design and requirements. fitting. The flowmeter measures the water flow and sends a signal to the motor driver control. Another FoamPro 1600 Series proportioners are designed sensing device monitors the foam pump output. for Class A foam concentrate (per NFPA 1150) Constant comparison of these two information signals applications. Full pump performance is realized by the computer ensures maintenance of the desired with concentrate viscosities up to 500 cps when proportion of foam concentrate at all times based on concentrate supply line design and installation the water flow rate, independent of any variations in recommendations are followed. As viscosity fire pump intake or discharge pressures. As water flow increases, diminished flow may affect pump increases or decreases, the foam concentrate rate of performance. Because of numerous variables; injection is increased or decreased automatically to including pump design, foam cell configuration, inlet correspond to the water flow. piping/components and system layout; please contact FoamPro at 800-533-9511 for application specific Foam concentrate is injected directly into the water recommendations when foam viscosities of 500 cps stream on the discharge side of the water pump. It or higher are used. is then fed as foam solution by the main fire pump into a standard fog nozzle, an air-aspirated nozzle, or CAFS equipment. Foam Tank Shut-off Calibrate/ Valve Inject Valve Water Tank Check Valve Line Check Strainer Valve Flowmeter Water Pump Single Discharge Coverage Multiple Discharge Coverage and Manifold Figure 1 FoamPro 1600/1601 System Layout 4 System 1600/1601 Installation and Operation Manual 3 System Component Description STANDARD FOAMPRO 1600/1601 EQUIPMENT The following components are packaged with the 6. Inlet Line Strainer with Nipple FoamPro 1600/1601: 1. Control Module with Instructions 7. FoamPro 1” bore x 1-1/2” NPT size, 1-1/2” 2. Molded Cables or 2” NPT Paddlewheel Flowmeter or 1-1/2” 3. Foam Pump Assembly or 2” Foam Manifold with Paddlewheel 4. Low-Level Sensor (One required. Flowmeter and Waterway Check Valve Not packaged with the unit. Order 8. 1/2” NPT Foam Injection Check Valve (This separately.) NFPA required check valve prevents water 5. Calibrate/Inject Valve with Bushing (Attached from back flowing into foam systems.) to the pump outlet connection.) 1 2 3 4 5 6 Side Mount (P/N 2510-0032) Vertical Mount (P/N 2510-0028) 7 8 5 Installation and Operation Manual SYSTEM ACCESSORIES AVAILABLE Polypropylene Foam Tank(s) 8 gallon, P/N 1530-0005 12 gallon, P/N 1530-0012 System Rating Placards System Placard 20 gallon, P/N 1530-0022 Model 1600, P/N 6032-0018 Single Tank, P/N 6032-0015 Model 1601, P/N 6032-0019 Nesconset, NY 11767 USA CAFS Power-Link Single Tank Flush Kits Interfaces FoamPro system with CAF system Both Internal and External flushing kits Solid State Contactor P/N 2510-0063 Internal Flush Kit, P/N 3430-0834 P/N 2510-0043 External Flush Kit, P/N 3430-0835 Main Waterway Check Valve All stainless steel with Victaulic Main Waterway Check Valve ends and injection and drain ports 1-1/2 inch NPT, P/N 3320-1001 1-1/2 pipe, P/N 3320-0069 Foam Manifold 2 inch NPT, P/N 3320-1002 2 inch pipe, P/N 3320-0070 1-1/2 inch Pipe,