Compressed Air Foam System Installation / Operation Manual Class1 ◆ A Unit of IDEX Corporation 607 NW 27th Avenue ◆ Ocala, FL 34475 U.S.A. Telephone: 352-629-5020 ◆ FAX: 352-629-3569 Web..........www.class1.
APPARATUS INFORMATION ENGINE ______________________________________________ TRANSMISSION _______________________________________ MAXIMUM CAFS ENGINE RPM ___________________________ CAFS ENGINE SPEED RANGE ___________________________ NOTICE ! Class1 cannot assume responsibility for product failure resulting from improper maintenance or operation. Class1 is responsible only to the limits stated in the product warranty. Product specifications contained in this manual are subject to change without notice.
Table of C ont ents ❑ Contents Page CAFSAttack Air Bottle System 1 Safety precautions ................................................................................................... 7 1.1 1.2 General Guidelines............................................................................................................. 7 Air Bottle Cylinders.......................................................................................................... 12 Brief Overview ....................................
❑ Ta ble of Contents Contents - continued 3.1 Page Receiving - continued Unpacking......................................................................................................................................... 24 Lifting The System............................................................................................................................ 24 4 Installation - Retrofit Full Size Pumper .............................................................. 25 4.1 General.................
Table of C ont ents ❑ Contents - continued 4.8 Page Electrical - continued Flow Sensor Connections (FM1 and FM2) ....................................................................................... 43 Air Supply Valve, Electric Motor (MV2).............................................................................................43 Discharge Valve, Electric Motor (MV1) .............................................................................................
❑ Ta ble of Contents Contents - continued Page Appendix B: Foam Concentrate Compatibility.................................................. 61 Reference ......................................................................................................................................... 63 Express Warranty .................................................................................65 Class 1..........................................................................................................
Saf ety Pre ca utions 1 ❑ Safety precautions IMPORTANT ! THE CLASS1 CAFSATTACK™ AIR BOTTLE COMPRESSED AIR FOAM SYSTEM IS DESIGNED FOR OPTIMUM OPERATOR SAFETY. FOR ADDED PROTECTION, PLEASE FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION AND ADHERE TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND WITHIN THIS MANUAL.
❑ Sa fet y Prec autions WARNING ! THE CAFSATTACK AIR BOTTLE (H-CYLINDER) ASSEMBLY IS HEAVY AND BULKY, WEIGHING OVER 500 LBS. (227 KGS.). ALWAYS REFER TO YOUR BILL OF LADING FOR THE ACTUAL WEIGHT. USE PROPER LIFTING SUPPORT DEVICES (OVERHEAD CRANE, STRAPS / CHAINS, ETC.) CAPABLE OF HANDLING THE LOAD WHEN MOVING OR INSTALLING THE ASSEMBLY. ATTACH LIFTING APPARATUS TO THE CYLINDER FRAME ONLY. DO NOT ATTACH STRAPS AROUND THE CYLINDERS., ESPECIALLY AT THE SHUT-OFF VALVE AREA.
Saf ety Pre ca utions ❑ Any of the preceding could effect system capacity and/or safe operation of the system and is a serious safety violation which could cause personal injury or death, could weaken the construction of the system or could affect safe operation of the CAFSAttack Air Bottle System. WARNING ! NO MODIFICATIONS OR ADDITIONS MAY BE MADE TO THE CAFSATTACK AIR BOTTLE SYSTEM WITHOUT PRIOR WRITTEN PERMISSION FROM: Class1 A Unit of IDEX Corporation 607 NW 27th Avenue Ocala, FL 34475 U.S.A.
❑ Sa fet y Prec autions Also see Tescom “Safety, Installation and Operation Precautions” guide lines, located at the back of this manual. If a balancing regulator valve or other component in the system shows signs of a leak or malfunction, the CAFSAttack system must be removed from service immediately and repaired and tested before retuning to service.
❑ Saf ety Pre ca utions ❑ Always disconnect the power cable, ground straps, electrical wires and control cables from the smart-switch control unit or other CAFSAttack system equipment before electric arc welding at any point on the apparatus. Failure to do so could result in a power surge through the unit that could cause irreparable damage. ❑ Before connecting the cord sets and wiring harnesses, inspect the seal washer in the female connectors.
❑ Sa fet y Prec autions 1.2 AIR BOTTLE CYLINDERS The CAFSAttack system uses HIGH pressure, compressed air storage cylinders (4,500 PSI / 310 BAR) which are in compliance with NFPA 1989 “Standard on Breathing Air Quality for Fire and Emergency Services Respiratory Protection.
❑ Saf ety Pre ca utions Also review and adhere to regulation NFPA 55: “Standard for the Storage, Use and Handling of Compressed Gases and Cryogenic Fluids in Portable and Stationary Containers, Cylinders, and Tanks.” CAUTION ! THE AIR CYLINDERS MUST BE FILLED WITH “BREATHING AIR” QUALITY AIR. HOWEVER, THIS AIR IS “NOT SUITABLE” FOR BREATHING AIR APPLICATIONS (SCBA). OPEN AND CLOSE AIR CYLINDER VALVES “SLOWLY.” ALWAYS “CLOSE” THE AIR VALVE WHEN THE CAFSATTACK SYSTEM IS NOT IN USE.
❑ Sa fet y Prec autions ❑ All materials used in the air system must be corrosion resistant or treated to resist corrosion unless the finished product is in continual contact with a noncorrosive lubricant. All pneumatic fittings, tubing and hoses must also be rated for the maximum allowable working system pressure. ❑ Flexible hose must be installed to prevent cuts, abrasions, exposure to damage, excessive temperatures, damage from loose equipment and excessive bending.
❑ De sc ription 2 Introduction 2.1 OVERVIEW The CAFSAttack Air Bottle Compressed Air Foam Pumping System is designed for installation on new or for retrofit onto existing fire apparatus. The CAFSAttack system must be considered an additional option on a fire fighting apparatus and must not impair the operation of the basic system. The performance of the original fire fighting system, as well as personal safety, must not be compromised.
❑ De sc ription Figure 2-1: CAFSAttack System Overview ❑ HIGH pressure valve assembly - continued ● Tee-type air filter - used to remove any particulate contaminates from the system. A multi-layered glass fiber element produces high efficiency silt-control filtration and provides for extended service intervals and reduced maintenance cost. A visual pressure indicator enables the operator to read contaminated build up before the element is plugged, with an automatic reset.
❑ De sc ription ● ❑ Paddle wheel flow sensors. CAFSAttack operator control panel ● Two Class1 “Smart-Switch” Controllers with LED bar graph array. ● Inteli-Tank high pressure air tank level indicator - four (4) RED indicators lights, indicates cylinder tank charge remaining. ● On/Off CAFSAttack air enable switch, to activate the CAFSAttack system. ● Amber HIGH pressure warning light, illuminates at pressures above 150 PSI (10 BAR).
❑ De sc ription Since the system is of the modular design, a minimum number of pneumatic and electrical connections are required. Mounting the FoamLogix 2.1A, 3.3 or 5.0 System includes installation of the foam pump and motor assembly, in-line strainer and valve assembly and low tank sensor. Refer to the following manual, based on the specific model FoamLogix included with your system: ❑ FoamLogix Model 2.1A Installation and Operation Manual, Hale p/n: 029-0020-74-0 ❑ FoamLogix Model 3.3 and 5.
De sc ription ❑ Figure 2-2: Smart-Switch Controller - SPC The OPEN button LED is ON steady during operation and flashes during setup. CLOSE Button, Discharge Valve The CLOSE button closes the water discharge valve to decrease the water or foam solution (making a dryer solution). Holding the button pressed closes the valve until the internal limit switch activates, indicating the fully CLOSED position. The CLOSE button LED is ON steady during operation and flashes during setup.
❑ De sc ription Pressing the WET button also immediately activates the FoamLogix controller in preparation for foam injection. When the system detects water is flowing, the appropriate air valve is opened. Press and Hold Press and HOLD the WET button for about ten (10) seconds to store a new WET CAFS consistency at Preset 2. The entire display blinks once when the setting is stored. Use the OPEN and CLOSE buttons to adjust the airto-foam solution ratio, thus the foam consistency.
❑ De sc ription IMPORTANT ! THE DUAL DISCHARGES AND SMART-SWITCH CONTROLLERS OFFER SEPARATE CONTROL FOR EACH DISCHARGE, I.E., ONE DISCHARGE CAN BE SET FOR WET CAFS WHILE THE OTHER IS SET FOR DRY CAFS. 2.3 CAFSATTACK OPERATOR CONTROL PANEL The CAFSAttack Operator Control Panel provides the means to enable (turn ON) the CAFSAttack system and to supply, monitor and charge the air pressure in the two DOT air cylinders. (See Figure 2-3: CAFSAttack Operator Control Panel.
❑ De sc ription HIGH Pressure Indicator Also see Figure 2-3: “CAFSAttack Operator Control Panel” on page 21. The HIGH pressure indicator (YELLOW) illuminates when the water/air pressure is greater than 150 PSI (10 BAR). Pressure in excess of 160 PSI (11 BAR) is discharged through the safety relief valve. Air Bottle OPEN/CLOSE Valve This open/close shut-off valve introduces HIGH air pressure to the system (0 = CLOSED; I = OPEN).
Rec eiv ing a nd Inspe ction 3 ❑ Receiving and inspection 3.1 RECEIVING Before shipping from Class1 the CAFSAttack Compressed Air Foam Pumping System is factory inspected and tested. However, we recommend that you: 1. Inspect the packaging for any signs of physical damage during shipment. Note any apparent damage on the bill of lading and request the delivery agent to sign it. Report the damage to Class1, Ocala, FL. and the shipping company. 2.
❑ Re ce iving and Ins pec tion ❑ Appropriate air injection hose, 1/4” (6 mm), up 6,000 PSI (414 BAR) ❑ Appropriate discharge hose or piping, 1/4” (6 mm), up ??? PSI (??? BAR) ❑ Appropriate electrical wire, Type SXL, GXL or TXL ❑ Appropriate DOT air injection tube, 3/8” (9.5 mm) ❑ Appropriate LOW pressure drain and HIGH pressure tubing / hose, recommended - 3/8” (10 mm), up 6,000 PSI (414 BAR) Unpacking The CAFSAttack system is shipped partially assembled on two skids.
❑ Ins talle r Insta llation 4 Installation - Retrofit Full Size Pumper 4.1 GENERAL Since most truck configurations are not the same, this section serves only as a general guide for installation. When installing the CAFSAttack system use the best accepted practices for mounting. Review previous Section 3 “Receiving and inspection,” beginning on page 23. Also see Figure 4-1: “CAFSAttack System Overview.
❑ Insta ller Ins ta lla tion 4.2 DOT AIR BOTTLE CYLINDER ASSEMBLY DANGER ! ALWAYS TREAT COMPRESSED AIR CYLINDERS WITH RESPECT. THEY CONTAIN VERY HIGH PRESSURES (UP TO 4,500 PSI / 310 BAR). READ THE MSDS AND FOLLOW PROPER PROCEDURES WHEN HANDLING AND USING THESE CYLINDERS. ALWAYS FOLLOW THE RECOMMENDED SAFETY PROCEDURES.
❑ Ins talle r Insta llation IMPORTANT! (SEE FIGURE 4-2: “DOT AIR BOTTLE CYLINDER ASSEMBLY LAYOUT DIMENSIONS,” ON PAGE 26.) WHEN DETERMINING THE LOCATION FOR THE AIR BOTTLE CYLINDER ASSEMBLY (WITH THE HIGH PRESSURE VALVE ASSEMBLY), IT IS RECOMMENDED TO INSTALL THE SYSTEM “ABOVE” THE PUMP WITH DOWNWARD SLOPPING LINES TO PROMOTE POSITIVE DRAINAGE.
❑ Insta ller Ins ta lla tion Figure 4-3: Pressure Balancing (Regulator) Valve Assembly Layout WARNING ! EXERCISE CARE NOT TO DAMAGE OR TWIST INTERCONNECTING HIGH PRESSURE PNEUMATIC PIPING OR ACCIDENTALLY LOOSEN FITTING CONNECTIONS DURING ASSEMBLY. REMEMBER, THE SYSTEM MUST BE HYDROSTATIC TESTED BEFORE USE AND SHIPPING TO THE CUSTOMER. 4.
Ins talle r Insta llation ❑ Note: For CAFSAttack systems, the main cable harness included with the FoamLogix system differs from what is shown in the FoamLogix manual. For an overview of the replacement cable used with CAFSAttack, see Section 7, “Drawing / Manual Package” on page 67. 4.5 CAFSATTACK OPERATOR PANEL LAYOUT (See Figure 4-4: “Operator’s Panel Layout Dimensions.
❑ Insta ller Ins ta lla tion 4.6 2. Consideration must be given for routing the HIGH pressure tubing / hoses and electrical harnesses. Make certain there is sufficient room behind the assembly. If necessary, order a longer or shorter harness to suit the location demands. 3. Modify the apparatus operator’s control panel to accept the CAFSAttack operator’s panel and placard. (See Figure 4-4: “Operator’s Panel Layout Dimensions.
❑ Ins talle r Insta llation The following components are pre-mounted on the SVS discharge manifold assembly. (See Figure 4-5: “Typical CAFSAttack SVS Discharge Manifold Assembly,” on page 30.) ❑ Electrically-operated Hale SVS valves, with valve position indicator. See separate manual for description, installation and operation of the SVS valves - Torrent SVS Valve Installation Operation and Maintenance Manual, Hale p/n: 029-0020-90-0. ❑ Mixing chambers, includes one 2.0” (51 mm) mixer insert.
❑ Insta ller Ins ta lla tion CAFSAttack Operator’s Control Panel Figure 4-6: Typical HIGH Air Pressure Connections WARNING ! THE CYLINDER PRESSURE LINES OPERATE AT PRESSURES UP TO 4,500 PSI (310 BAR). ALL FITTINGS, TUBING, ETC. SHOULD BE THE FLARED TYPE AND MUST BE RATED FOR THE MAXIMUM SYSTEM OPERATING PRESSURE. IF HOSE IS REQUIRED, USE 3/8” (10MM) MINIMUM TO 1/2” (13MM), WIRE REINFORCED HOSE, SUCH AS AEROQUIP FC350-16 FOR MAXIMUM AIR FLOW. 1.
❑ Ins talle r Insta llation It is preferred to run 3/8” (10 mm) high pressure tubing with flared ends for connection to the appropriate fittings. Also see WARNING ! on page 32. 2. Ensure the hose or tubing is adequately secured against stresses, vibrations and other conditions incident to being mounted on a fire apparatus and being used in mobile service. 3.
❑ Insta ller Ins ta lla tion Figure 4-7: 4,500 PSI HIGH Pressure Balancing Regulator and Dome Connections 9. Plumb a 3/8” (9.5 mm) tubing line between the bottom or dome port on the balancing regulator valve to the pump discharge for waterto-air operating pressure balance. (See Figure 4-8: “Pump-to-Balancer Valve Dome Connection.
❑ Ins talle r Insta llation Intake Air Pressure Gauge Layout Option An “optional” high pressure gauge is available, Class1 p/n: ??, to provide accurate intake air pressure monitoring (up to 7,500 PSI / 517 BAR) during system operation and cylinder tank refill. (See Figure 4-9: “Typical Intake Air Pressure Gauge Layout.
❑ Insta ller Ins ta lla tion Figure 4-10: Typical LOW Pressure CAFS Air Connections WARNING ! THE LOW PRESSURE CAFS LINES OPERATE AT PRESSURES OF APPROXIMATELY 150 PSI (10 BAR). ALL FITTINGS, TUBING, ETC. USED MUST BE RATED FOR THE MAXIMUM CAFS SYSTEM DISCHARGE OPERATING PRESSURE. LOW PRESSURE LINES MUST ALSO BE ADEQUATE FOR OPERATING TEMPERATURES FROM -30° F TO +140° F (-34° C TO +60° C). 2.
❑ Ins talle r Insta llation 3. A method for discharge draining / flushing (possible tee fitting) must also be provided. (See heading “ Air Discharge Moisture Drain” on page 37.) 4. Use a suitable sealing compound (for example, Loctite PST) on all fitting threads. Air Discharge Moisture Drain (See Figure 4-11: “Typical Discharge Drain.”) The installer/ builder must supply individual moisture drain lines and valving (3/4” / 9.
❑ Insta ller Ins ta lla tion CAFS Air LOW Pressure Gauge Layout Option An “optional” numeric-display, low or CAFS air pressure gauge is available, Class1 p/n: 91220001, to show the air pressure being delivered to the foam discharge manifolds. (See Figure 4-13: “CAFS Air LOW Pressure Layout Option,” on page 38.) The gauge should be mounted in the area of the CAFSAttack operator’s panel and plumbed in the system after the pressure balancing regulator valve.
❑ Ins talle r Insta llation CAUTION ! ❑ Review the “Safety” section of this manual, beginning on page 7, in its entirety before proceeding with electrical connections. ❑ To prevent system damage or electrical shock the main power supply wire must be the last connection made. ❑ The cables provided with each CAFSAttack system contain shielded assemblies. NEVER attempt to shorten or lengthen these shielded cables.
❑ Insta ller Ins ta lla tion Smart-Switch Controller - SPC (S1 and S2) For the suggested panel installation and cutout dimensions see Figure 414: “Smart-Switch Controller Panel Cutout” on page 40. Determine a location on the apparatus pump operator panel for the smartswitch controllers (2). Consideration must be given for routing the interconnecting cable from the controller to the foam discharge assembly and the high pressure transducer assembly.
❑ Ins talle r Insta llation Add a service loop to avoid strain on the wires or connectors during body and frame flex. Also see Figure 4-17: “Extra Cable Storage” on page 43. CAFSAttack Main Wire Harness The system installer must provide an extension main power and ground wire cable for the Class1 CAFSAttack system. (See heading “ Primary Power and Ground” on page 42.) Also see Figure 4-16: “Primary CAFS Wire Harness.
❑ Insta ller Ins ta lla tion IMPORTANT - continued ! WHEN PLANING CABLE RUNS MAKE SURE THE WIRES ARE ROUTED BY THEIR SHORTEST MOST DIRECT ROUTE, STABILIZED AGAINST EXCESSIVE VIBRATION AND ROUTED TO AVOID INTERFERENCE WITH THE APPARATUS OPERATORS. For complete cable design of the standard harness (Class1 p/n: 112757) and for the Triple Discharge Option harness (Class1 p/n: 114810), also see Section 8, heading “Drawing / Manual Package” on page 67.
❑ Ins talle r Insta llation RFI / EMI A 100% electrically shielded main cable harness is provided with the Class1 CAFSAttack system to eliminate the potential problem of RFI / EMI. Proper installation of system components and cables, along with proper grounding, limits radio interference caused by the CAFSAttack system. Additionally, make sure radio cables and hardware are not located in the immediate area where the CAFSAttack system is mounted.
❑ Insta ller Ins ta lla tion NEVER attempt to shorten or lengthen these shielded cables. If necessary order longer or shorter cables from Class1 to suit your particular installation needs. Wire used is minimum 18 AWG type SXL/GXL (SAE J1128) Wire. Discharge Valve, Electric Motor (MV1) Connect the main cable harness (connectors #3 and #9) to the ?-pin connectors on the discharge air valve electric motors. (See Figure 4-16: “Primary CAFS Wire Harness,” on page 41.
❑ St art Up Che ck Lis t 4.9 INSTALLATION AND DELIVERY CHECK LIST After the CAFSAttack system is installed, use the following check list to verify installation and ensure proper system startup when the apparatus is delivered to the end user. Installation Date Initials _______ _______ _______ _______ ❑ CAFSAttack system is properly installed. See Section 4 “Installation - Retrofit Full Size Pumper” on page 25. ❑ Review previous Section 4.7 “Plumbing,” beginning on page 31.
❑ Sta rt U p Chec k List 4.10 START UP CHECK LIST Before energizing the apparatus and the CAFSAttack system for the first time make sure the following items are checked: Electrical ❑ Main cable harness connections are correct and tight. (See Figure 4-16: “Primary CAFS Wire Harness,” on page 41.) ❑ All cables and wires are secured and protected from damage during operation. ❑ Flow sensor cable properly connected to main cable harness (C1 and C7).
❑ St art Up Che ck Lis t WARNING ! - continued THE HIGH PRESSURE SIDE IS BLED (PRESSURE RELIEVED) BY FIRST MAKING SURE THE CYLINDER SHUT-OFF VALVE IS FULLY CLOSED. THEN SLIGHTLY LOOSENING THE HOSE FITTING NUT AT THE CYLINDER SHUTOFF VALVE UNTIL YOU HEAR AIR ESCAPING FROM THE FITTING. AN ALTERNATE METHOD IS TO INSTALL AND SHUT-OFF VALVE IN AN ACCESSIBLE AREA IN THE HIGH PRESSURE LINE. ALSO SEE HEADING “RELIEVING HIGH PRESSURE” ON PAGE 59.
❑ Sta rt U p Chec k List 4.11 SYSTEM INSTALLER START-UP When energizing the CAFSAttack system at the system installer facility for the first time the following procedures shall be used. Initial System Power Check 1. To check the HIGH pressure lines, SLOWLY open the cylinder shut-off valve to gradually pressurize the HIGH pressure side of the system. (See Figure 4-1: “CAFSAttack System Overview,” on page 25.) 2. Check each connection for leaks.
St art Up Che ck Lis t ❑ For CAFSAttack ??? CAFS Bottled-Air Operator/s Guide p/n: 029-0020-85-0 49
❑ Sta rt U p Chec k List Notes ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ __________________________________________________________________
❑ Pres et C alibra tion / Operation 5 Preset calibration This section details the calibration process for the Smart-Switch controllers, Presets 1 and 2. When the apparatus is delivered to the end user facility the foam tank(s) must be filled with the specified foam concentrate(s) intended for use. Make sure the proper foam concentrate is placed into the correct tank. The system must then be adjusted to operate with the end user foam concentrate(s) for best accuracy.
❑ Pres et C alibra tion / O peration Recalibration may be required ONLY after major repairs or component changes are made to the CAFSAttack system or when a different viscosity of foam concentrates is needed (wetter or dryer). IMPORTANT ! THERE IS A SMART-SWITCH CONTROLLER FOR EACH AIR CYLINDER. THEREFORE BOTH NEED TO BE ADJUSTED, ALTHOUGH THEY CAN BE ADJUSTED DIFFERENTLY FOR INDIVIDUAL CAFS RESULTS.
❑ Pres et C alibra tion / Operation 6. Begin discharging CAFS in accordance with departmental or locality regulations. If you are satisfied with the results, continue with Step 8. to store the setting. 7. Use the OPEN and CLOSE buttons on the smart-switch to change the CAFS consistency to the desired WETNESS (press OPEN for WETTER; press CLOSE for DRYER consistency). 8.
❑ Pres et C alibra tion / O peration 6. Begin discharging CAFS in accordance with departmental or locality regulations. If you are satisfied with the results, continue with Step 8. to store the setting. 7. Use the OPEN and CLOSE buttons on the smart-switch to change the CAFS consistency to the desired DRYNESS (press OPEN for WETTER; press CLOSE for DRYER consistency). 8.
❑ Pres et C alibra tion / Operation ❑ The intelli-tank air level display illuminates to show the air-remaining level in the cylinders. (See Figure 2-3: “CAFSAttack Operator Control Panel,” on page 21.) Note: The air level indicator lights are an accumulation of both cylinders. See separate manual, located at the back of this manual, for additional information. IMPORTANT ! KEEP IN MIND THAT THERE IS A SMART-SWITCH CONTROLLER FOR EACH AIR CYLINDER.
❑ Pres et C alibra tion / O peration 5A.2 SHUTTING-DOWN CAFSATTACK IMPORTANT ! WHEN CAFS OPERATION IS COMPLETE, SET THE AIR BOTTLE VALVE HANDLE TO THE CLOSE (O) POSITION. DANGER ! NEVER FULLY EMPTY THE CAFSATTACK AIR CYLINDERS. ALWAYS MAINTAIN POSITIVE PRESSURE IN THE CYLINDERS TO PREVENT MOISTURE AND/OR DIRT CONTAMINATION. AN INDICATION OF A “LOW” CHARGE IN TO AIR BOTTLES IS WHEN THE BOTTOM LIGHT ON THE INTELLI-TANK DISPLAY FLASHES.
Routine Mainte nance 6 ❑ Routine maintenance 6.1 MAINTENANCE PROCEDURES After each use ❑ Inspect wiring, hoses, flow sensors and connections for tightness, corrosion, leaks and/or damage. (See Section 4, heading 4.7 “Plumbing,” on page 31.) Also see Section 4, heading “Electrical” on page 38. ❑ Verify status of the CAFSAttack air filter element. See heading 6.2 “Replace Filter Element” on page 58. ❑ Clean inspect the CAFSAttack system for after each use.
❑ Routine Ma int enanc e ❑ If an approved foam concentrate has been left in the system, operate the FoamLogix to move the foam concentrate and prevent jelling. Annually 6.2 ❑ See your specific FoamLogix manual, provided with the system, for maintenance procedures. ❑ Verify foam feedback calibration. REPLACE FILTER ELEMENT A visual pressure indicator (plunger) shows the contaminated build up to alert the operator when the filter element must be changed.
❑ Routine Mainte nance 5. 6.3 Apply light lubricant (oil) to the O-ring seal and thread and tighten the case to the housing base. RELIEVING HIGH PRESSURE DANGER ! ONCE THE AIR CYLINDERS ARE FULLY CHARGED AND THE SYSTEM IS ENERGIZED, ALL HIGH PRESSURE LINES BETWEEN THE CYLINDER SHUTOFF VALVES AND THE PRESSER BALANCING REGULATOR VALVES, INCLUDING THE AIR FILTER, ARE EXPOSED TO HIGH PRESSURES (4,500 PSI / 310 BAR). DO NOT PERFORM ANY SERVICE TO THE HIGH PRESSURE SIDE UNTIL THE SYSTEM PRESSURE IS RELIEVED.
❑ Routine Ma int enanc e Notes ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ _______________________________________
H ale Foam Conce nt ra te C om pa tibility C ha rt ❑ Appendix B: Foam Concentrate Compatibility The following foam concentrates are approved for use in Hale Foam Proportioning Systems. The Class “A” foam concentrates are approved for use in all Hale Foam Proportioning Systems (i.e., Hale FoamLogix 5.0, 3.3, 2.1 and Hale V Series).
❑ Ha le Foa m Conc entrat e Compat ibility Cha rt Type of Foam Concentrate Manufacturer Brand Name CLASS “B” FOAM * The Class “B” Foam, Specialty foam and Fire Fighting Additive Concentrates are approved for use in FoamLogix Models 5.o and 3.3 Foam Proportioning System only. AFFF Alcohol Resistant Concentrate Reference * Note: This list of compactible foam concentrate is updated regularly. For latest information see www.haleproducts.com.
H ale Foam Conce nt ra te C om pa tibility C ha rt ❑ Reference The preceding foam concentrates have been tested by Hale Products to ensure compatibility with Hale FoamLogix models 5.0 and 3.3 Foam Proportioning Systems. These chemicals were run for several hundred hours over several months to make sure they do not harm the Foam System. This list is solely intended to assist the end user in selection of foam concentrate(s) compatible with a Hale FoamLogix Model 5.0 and 3.
❑ Ha le Foa m Conc entrat e Compat ibility Cha rt Hale Products Inc. A Unit of IDEX Corporation 700 Spring Mill Avenue Conshohocken, PA 19428 U.S.A. Telephone..............1-610-825-6300 Fax ........................1-610-825-6440 Web ........ www.haleproducts.com 64 www.haleproducts.com/products/foam Rev.
Limited Warranty Express Warranty EXPRESS WARRANTY: Hale Products, Inc. (HALE) hereby warrants to the original Buyer that products manufactured by Hale are free of defects in material and workmanship for one (1) year. The “Warranty Period” commences on the date the original Buyer takes delivery of the product from the manufacturer. LIMITATIONS: Hale’s obligation is expressly conditioned on the Product being: ● Subjected to normal use and service.
Class1 A Unit of IDEX Corporation 607 NW 27th Avenue Ocala, FL 34475 U.S.A. Telephone................... 352-629-5020 Fax.. ........................... 352-629-3569 Web .....................www.class1.
Compressed Air Foam System Drawing / Manual Package Class1 ◆ A Unit of IDEX Corporation 607 NW 27th Avenue ◆ Ocala, FL 34475 U.S.A. Telephone: 352-629-5020 ◆ FAX: 352-629-3569 Web..........www.class1.
Contents 7 Drawings / Manuals.................................................................. Part Number Drawings - CAFSAttack Air Bottle System Block Diagram ........................................................................................................................ ? Electrical Schematic .......................................................................................................114845 Logix Air TLG Harness Diagram..................................................................
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S31 P14-10R Pin WireName 1 PWR INSTR 1 S32 P14-10R S32 S31 3 IL11 PNF14-4R-3K Pin WireName 1 GND_3 Pin WireName 1 CAFS ON OFF 3 3 IL12 PNF14-4R-3K 3 IL11 IL12 Pin WireName 1 HP SW GND 6 PWR 12010974 SPL2 TLG 2 SPL1 1 4 0 2 3 PWR 6 TLG 776286-1 Pin WireName 1 PWR INSTR 2_1 2 GND_1 Pin WireName A PWR INSTR 3 B GND_2 C HP SW GND D PWR INSTR 2_2 12 3 30 4 5 6 SENSOR PWR POS 5 7 SENSOR SIGNAL 8 SENSOR GND XDCR FLX XDCR 12065287 Pin WireName A SENSOR
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Installation Instructions For EZ-View® Flow Meter and EZ-View® Flow Alert Flow Meter 2200 South Street • Racine • Wisconsin 53404 TEL 262-639-6770 • FAX 1-800-CHK-FLOW or 262-639-2267 HLIT 300 CAUTION This product should be installed and serviced by technically qualified personnel trained in maintaining industrial class flow instrumentation and processing equipment. CAUTION Read instructions thoroughly before installing the unit.
EZ-View ® Flow Meter and EZ-View ® Flow Alert Flow Meter Installation & Maintenance Instructions III. SPECIFICATIONS Accuracy • ± 5% of full scale Repeatability • ± 1% Pressure • • Liquids: Air/Gases: 325 PSI (22.4 bar) Maximum 125 PSI (8.
VI. MAINTENANCE EZ-View ® Flow Meter and EZ-View ® Flow Alert Flow Meter Installation & Maintenance Instructions EZ-View Flow Meters are designed to provide many years of service with little or no maintenance requirements. Periodic cleaning may be required. • • • Clean the outside of the flow meter with denatured alcohol or mild detergent and warm water. Should the inside of the flow meter become stained, it can be disassembled for cleaning.
EZ-View ® Flow Meter and EZ-View ® Flow Alert Flow Meter Installation & Maintenance Instructions MANUFACTURER'S ONE YEAR WARRANTY The HEDLAND Division of Racine Federated, Inc. warrants to the original purchaser, for the period of one year from the date of purchase, that each flow meter is free from defect in materials and workmanship.
Intelli-Tank Water/foam tank level display utilizing a 0-5 PSI transducer Contents ………………………………………………….. 1 Overview ………………………………………………….. 2 Operation ………………………………………………….. 3 Installation ………………………………………………….. 5 Wiring ………………………………………………….. 7 Calibration ………………………………………………….. 9 Dim function ………………………………………………….. 11 Self test ………………………………………………….. 11 Passwords ………………………………………………….. 12 Troubleshooting …………………………………………………..
The Intelli-Tank 4 light tank level is designed to display a liquid’s volume to an eighth of a tank level accuracy through 180-degree viewable ultra-bright LEDs. The unit set as a Master uses a 0 – 5 PSI pressure transducer to obtain tank level information and then relays that information along the data line to units set as Remotes. Multiple Remote units can be linked to the Master tank level unit.
When the unit is first powered up the LEDs will cycle on individually starting with the EMPTY (bottom) LED and then the LEDs will show current status. • A Master unit properly connected to a functioning transducer will display current tank level information. • A Master unit not connected to a pressure transducer will alternately flash the bottom two LEDs. • A Remote unit connected to a Master unit (through the 1-wire data line) will mimic the Master unit’s LED condition and flash rate.
Miscellaneous indications: Condition LED 4 LED 3 LED 2 LED 1 Invalid calibration AlternaFLASH AlternaFLASH EEPROM error AlternaFLASH AlternaFLASH Signal voltage above AlternaFLASH AlternaFLASH 4.8V Signal voltage below AlternaFLASH AlternaFLASH .4V Remote “NO DATA” AlternaFLASH AlternaFLASH User Error (wave off) 4 quick cycles ON ON ON ON The tank level has two flash rates: FAST (1.6Hz) and SLOW (.8Hz). AlternaFLASH flashes two lights alternately at the SLOW flash rate.
Intelli-Tank display The display requires a cutout as shown. The unit is water tight and may be mounted in any location on the operator’s panel. Outer bezel dimensions.
Before mounting the display and adhering the label insure that the unit is situated correctly (TOP is UP). Refer to the drawing for orientation. Pressure Transducer The transducer has a ¼” NPT mount and must be mounted vertically as depicted to insure an accurate reading.
Power and Ground It is imperative that a system utilizing Master and Remote tank level units connected by the 1-wire data line have a common ground. Pin 1 Vehicle power Pin 2 Ground Dim Function The LEDs on the tank level unit can be dimmed to a user selectable dim setting by applying vehicle voltage to the Dim display Input.
Typical installation layout.
The Intelli-Tank display can be calibrated three different ways: 2-point (level calibration), 5-point and 9-point (volume calibration). To enter calibration mode use a magnet and activate the magnetic switches in the order of the appropriate password. When a magnetic switch is activated the display will indicate which switch was activated (Left = upper two LEDs, Right = lower two LEDs) for approximately half a second and then the display will go blank.
The unit will respond by flashing the two center LEDs the same number of times as the desired calibration. The unit will then indicate the level to be calibrated by lighting the proper LEDs for that level starting with empty (see page 3, tank level indications). When the tank is filled to the proper level for calibration (dictated by the LEDs) activate the RIGHT switch to store that point. The unit will flash the top LED and then set the LEDs for the next calibration point.
Dimming the Display The display can be dimmed by applying VIGN to pin 3 (Dim Display input). To select the dim level of the display use the magnetic switches to enter the password RLLR LLLR all of the LEDs will come on. Hold the magnet against the RIGHT switch and the display will either brighten or dim. Release the magnet and again hold it against the RIGHT switch and the display’s brightness will move in the opposite direction. When the dim level is at the desired point activate the LEFT switch.
RLLR LLRL 2 point calibration RLLR LRLR 5 point calibration RLLR RLLR 9 point calibration RLLR LLRR Self test RLLR LLLL Configure unit as Remote unit RLLR LLLR Configure dim level Software revision check Hold a magnet on the LEFT magnetic switch while powering the unit. The LEDs will display the software revision. (Use the chart below to decipher). Example. (LED 4 – OFF, LED 3 – ON, LED 2 – OFF, LED 1 – ON) = Ver 1.
Condition Evaluate Bottom two LEDs alternate flashing. Check transducer wiring. Ensure +5V at pin A, ground at pin B and at least .4V at pin C (Signal). Unit fails self test, LED 1 flashing. Top two LEDs alternate flashing. Check transducer wiring. Ensure +5V at pin A, ground at pin B and no more than 4.8V at pin C (Signal). Unit fails self test, LED 1 on. Middle two LEDs alternate flashing. Perform self test. If it fails with LED 3 on replace unit. Outer two LEDs alternate flashing.
Condition Evaluate Check for large noise spikes on the data line. The bottom two LEDs are on and Insure that the unit’s ground potential is the same as the Master’s. occasionally they go Insure that the data line is not chaffed and making contact with out and the top two other electrical wires. flash and then return to the bottom two LEDs on (or viceversa). (REMOTE). The points calibrated seemed to have changed. Self test the unit to check for any malfunctions. Unit will not dim display.
Safety, Installation, & Operation Precautions INDUSTRIAL CONTROLS DIVISION DO NOT ATTEMPT TO SELECT, INSTALL, USE, OR MAINTAIN THIS REGULATOR, VALVE, OR ACCESSORY UNTIL YOU HAVE READ AND FULLY UNDERSTAND THESE INSTRUCTIONS. BE SURE THIS INFORMATION REACHES THE OPERATOR AND STAYS WITH THE PRODUCT AFTER INSTALLATION. DO NOT PERMIT UNTRAINED PERSONS TO INSTALL, USE, OR MAINTAIN THIS REGULATOR, VALVE, OR ACCESSORY.
WARNING SAFETY PRECAUTIONS (Continued): construct vent lines to prevent condensation or gas accumulation. Make sure the vent outlet is not obstructed by rain, snow, ice, vegetation, insects, birds, etc. Do not interconnect vent lines; use separate lines if more than one vent is needed. 20. Do not locate regulators, valves, or accessories using flammable fluids near open flames or any other source of ignition. 21. Some fluids when burning do not exhibit a visible flame.
Class1 A Unit of IDEX Corporation 607 NW 27th Avenue Ocala, FL 34475 U.S.A. Telephone................... 352-629-5020 Fax.. ........................... 352-629-3569 Web .....................www.class1.
