ROTARY GEAR PUMP ELECTRONIC FOAM PROPORTIONING … · ROTARY GEAR PUMP ELECTRONIC FOAM...

6/1/99

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

ROTARY GEAR PUMPELECTRONIC FOAM

PROPORTIONING SYSTEM

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.

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

Hale FoamMaster System Serial Number: ____________________________

NOTICE: This manual is divided into four sections for clarity and ease of use. Section I: DESCRIPTION; Provides anintroduction to the Hale Foammaster System along with guidelines for designing and ordering a complete system.Section II: INSTALLATION; Provides information to assist the OEM with installation and initial set-up of Hale FoamMastersystems on an apparatus. Section III: SET-UP AND CALIBRATION; Is used by the installer and end user for start-up andcalibration of the Hale FoamMaster system. Section IV: OPERATION; Is primarily used by the apparatus user for properoperation and maintenance of the Hale FoamMaster system. Each manual section can be a stand alone section orcan be used in conjunction with each other.

MANUAL P/N 029-0020-35-0, REV E, © 1999 HALE PRODUCTS, INC., PRINTED IN U.S.A.

Description, Installation and Operation Manual i

ROTARY GEAR PUMPELECTRONIC FOAM PROPORTIONING SYSTEM

TABLE OF CONTENTSChapter Title PageSECTION I: DESCRIPTION

SAFETY .................................................................................................................................... I-1SYSTEM DESCRIPTION ............................................................................................................ I-3Hale FoamMaster SYSTEM SPECIFICATIONS ....................................................................... I-6SYSTEM CONFIGURATION ..................................................................................................... I-8SYSTEM DIAGRAMS ............................................................................................................. I-17

SECTION II: INSTALLATIONSAFETY ................................................................................................................................... II-1APPARATUS INSTALLATION PLANNING ............................................................................... II-3INSTALLER SUPPLIED COMPONENT RECOMMENDATIONS ............................................... II-5FOAM PUMP MOUNTING..................................................................................................... II-9PLUMBING COMPONENT INSTALLATION.......................................................................... II-12SYSTEM PLUMBING DIAGRAMS ......................................................................................... II-24ELECTRICAL INSTALLATION ................................................................................................ II-32Hale FoamMaster SYSTEM ELECTRICAL DIAGRAMS ....................................................... II-42START-UP CHECKLIST .......................................................................................................... II-44SYSTEM INSTALLER START-UP .............................................................................................. II-45

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

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

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

MAINTENANCE .................................................................................................................. IV-15TROUBLESHOOTING ..........................................................................................................IV-16PARTS IDENTIFICATION ...................................................................................................... IV-22WARRANTY ......................................................................................................................... IV-29

System installer must provide two copies of this Hale FoamMaster System Description, Installationand Operation 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 029-0020-35-0.

DESCRIPTION, INSTALLATION AND OPERATIONMANUAL

ROTARY GEAR PUMPELECTRONIC FOAM PROPORTIONING

SYSTEM



SECTION IDESCRIPTION

NOTICE: This manual section provides a general description of the Hale Foammaster Systemalong with guidelines for designing and ordering a complete system. This manual section can beused as a stand alone section or in conjunction with other sections of the complete manual.

Ι-1


Section ΙΙΙΙΙ: Description

SAFETYHale FoamMaster systems are designed to provide reliable and safe foam concentrateinjection. Before installing or operating a Hale FoamMaster system read all safetyprecautions and follow carefully 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 FoamMaster 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 HaleFoamMaster 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 FoamMastersystem be careful of rotatingcomponents.

CAUTIONS1. Foam tank low level sensors must be

utilized to protect the Hale FoamMasterfrom dry running. Failure to use low levelsensors with the Hale FoamMastersystem 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 FoamMaster 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 FoamMaster unit.

6. Before connecting the cordsets inspectthe seal washer in the femaleconnector. If the seal washer is missingor damaged, water can enter theconnector causing corrosion of the pinsand terminals resulting in possible systemfailure.

7. Always disconnect the power cable,ground straps, electrical wires andcontrol cables from the control unit orother Hale FoamMaster 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 FoamMaster Model 3.3 andModel 5.0 require 60 AMP minimumcurrent. The Hale FoamMaster Model3.0 requires 40 AMP minimum current.Use correct gauge wire as specified.

9. When operating the Hale FoamMaster 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 Hale FoamMaster ADTtoggle switch or Hale FoamMaster MDT IIselector handle must be in the TANK Aposition. If the toggle switch or selectorhandle is in the FLUSH position when theHale FoamMaster foam pump is startedthe foam pump will only run for 20seconds and shut down.

Ι−2 Section ΙΙΙΙΙ: Description


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.

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 Hale FoamMaster 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 HaleFoamMaster 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.

6. 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.

7. The cordsets provided with each HaleFoamMaster 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 HaleFoamMaster system are indexed so they

only go in the correct receptacle andthey can only go in one way. Whenmaking cordset connections DO NOTforce mismatched connections asdamage can result in improper systemoperation.

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

10. The cables shipped with each HaleFoamMaster 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 servicable parts insideHale FoamMaster system electrical/electronic components. Opening ofthese components (distribution box,control unit, foam discharge multiplexingdisplay unit) will void warranty.

12. 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.

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

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

15. 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.

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

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

Ι-3



SYSTEM DESCRIPTIONbutton while the system is operating. Thecontrol unit display also warns the operatorwhen errors or abnormal operations occurin the system.

Foam concentrate injection rate iscontrolled by an Intel® 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 FoamMaster system isactivated at the control unit a signal is sentfrom the control unit through the shieldedcontrol cable to the distribution box tobegin foam concentrate injection. Thedistribution box then provides power to theelectric motor. As the motor rotates thepump, foam concentrate flows through thefoam pump discharge to the one piececheck valve/injector fitting into the waterdischarge stream.

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 three models of Hale FoamMastersystems covered by this manual. The HaleFoamMaster Model 3.0, Model 3.3 andModel 5.0. The maximum rated foamconcentrate flow in gallons per minute isdenoted by the model number. Table 1shows system capacities at various foamconcentrate injection rates for the differentHale FoamMaster Models.

Hale FoamMaster foam proportioningsystems are completely engineered, factorymatched foam proportioning systems thatprovide reliable, consistent foamconcentrate injection for Class A and ClassB foam operations. Hale FoamMastersystems accurately deliver from 0.1% to10.0% foam concentrate through a checkvalve/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 HaleFoamMaster system with Halerecommended components virtuallyeliminates contamination of the boostertank, fire pump and relief valve with foamconcentrate.

The heart of the Hale FoamMaster system isan electric 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 HaleFoamMaster system. Depressing the ONbutton starts foam concentrate injection. Asuper brite digital LED display shows thewater flow 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 a



Hale FoamMaster systems can beconfigured to operate with single or dualfoam concentrate tanks. Examples of thevarious Hale FoamMaster systemconfigurations are shown in figures 1-1through 1-6 at the end of this section.

The available Air Dual Tank (ADT) valve forthe Hale FoamMaster system is an airoperated foam tank selector valve thatprovides selection of foam concentratedependent on fire ground operationaldemands. The ADT is an integral part of thefoam pump and provides an electricalinterlock for the low tank level sensors andconcentrate injection rate. A panelmounted selector toggle switch withindicator lights controls foam concentratetank selection and shows which foamconcentrate tank is in use.

The Manual Dual Tank (MDT ΙΙ) selectorvalve is available for the Hale FoamMastersystems with dual tanks. The MDT ΙΙ is apanel mounted manually operated selectorthat provides selection of foamconcentrate dependent on fire groundoperational demands. The MDT ΙΙ alsoprovides an electrical interlock for the lowtank level sensors and concentrate injectionrate. It should be noted that the MDT ΙΙ isnot suitable for top mount operator panelinstallations and some side operator panelsdue to gravity feed requirements of foamconcentrate.

Selection of the desired foam concentratetank with the ADT panel mounted toggleswitch or MDT ΙΙ selector will automaticallychange the foam concentrate injectionrate to the preset default rate for theselected foam tank. No further operatorintervention is required.

Single tank Hale FoamMaster systems canbe configured with a Manual Single Tank(MST) selector which provides a flushfunction connection to the HaleFoamMaster electronic controls.

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

Strainers available for Hale FoamMastersystems protect the foam pump from debristhat might accumulate in the foamconcentrate tank. The standard in-linestrainer/valve assembly has a compositenon-metallic housing with stainless steelmesh strainer element. It is provided with aservice shutoff valve, mounting bracket andfittings for connection of either 1 inch (25mm) ID or ¾ inch (19 mm) ID foamconcentrate 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.

WATER FLOWMODEL 3.0 MODEL 3.3 MODEL 5.0

FOAMCONCENTRATE

(%)

0.10.20.30.5136

GPM LPM

3000 113551500 56781000 3785600 2271300 1136100 37950 189

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

Ι-5



All Hale FoamMaster systems require at leastone flowsensor for operation. Some systemsmay be designed to operate using multipleflowsensors for a wide range of dischargeflows. When 2 or more flowsensors (up toeight) are installed on an apparatusequipped with a Hale FoamMaster system,Foam Discharge Multiplexing Display Unitsmust be installed. Each multiplexing unitreceives a signal from an individualflowsensor and provides a constant digitalreadout of flow in the monitored discharge.The multiplexing units are interconnectedand the final unit is connected to thecontrol unit. The control unit provides adigital readout of the total flow in allflowsensor monitored discharges.Additionally, a pressure transducermounted in the discharge piping provides asignal that is shown on the multiplexing unitbargraph as the discharge pressure. A pushbutton on the multiplexing unit gives adigital readout of the discharge pressure.The multiplexing unit is used on the operatorpanel instead of analog line pressuregauges.

Ordering of Hale FoamMaster systems issimple. Using the current Hale FoamMasterSystem Price List and Order Form helpsensure a complete matched system isprovided to the end user. Use the followingprocedure when ordering a HaleFoamMaster system:

1. Determine the type of foamconcentrate to be used in the systemand ensure system compatibility byreferring to the Hale FoamMasterConcentrate Compatibility list (Bulletin#650).

2. Determine the Hale FoamMaster systemdesired (Model 5.0, Model 3.3 or Model3.0; 12 VDC or 24 VDC motor; control

cable length,16.5 feet or 6.5 feet).3. Determine tank selector desired based

on the number of foam concentratetanks installed (ADT or MDT ΙΙ for dualtank systems; MST or No Selector forsingle tank systems).

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

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

6. Determine the size of flowsensor desiredbased on minimum and maximumdischarge flow (HPF40, HPF30, HPF25,HPF20 or HPF15; flowsensor cable length,16.5 feet or 6.5 feet).

7. If multiple flowsensors are requireddetermine the number of foamdischarge multiplexing display units toorder.

8. Determine additional Hale componentsthat enhance system operation andease installation (Waterway CheckValves, Manifolds, Flanges, etc.).

A complete Hale FoamMaster systemrequires steps 1 through 6 above.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 HaleFoamMaster systems to provide optimumsystem performance. Using the informationprovided in this manual section and thedetailed ordering procedures on the optionorder form ensures a complete HaleFoamMaster system is ordered thuseliminating delays caused by missingcomponents.



Hale FoamMaster Installation Envelope DimensionsConfigured for use with MDT ΙΙ , MST or No Tank Selector Option

9.43 IN.(240 MM)

¾ INCH NPT SUCTIONHOSE CONNECTION

½ INCH NPT INJECTHOSE CONNECTION

½ INCH NPT BYPASS HOSECONNECTION

MODEL 5.0: 22.00 IN. (559 MM)MODEL 3.3 & MODEL 3.0: 21.75 IN. (552 MM)

6.02 IN.(153 MM)


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

Model 3.0 ........................................................................................................ 3.0 GPM (11 LPM)Model 3.3 ........................................................................................................ 3.3 GPM (12 LPM)Model 5.0 ........................................................................................................ 5.0 GPM (19 LPM)

Maximum System Operating PressureModel 3.0 ......................................................................................................... 250 PSI (17 BAR)Model 3.3 ......................................................................................................... 400 PSI (28 BAR)Model 5.0 ......................................................................................................... 250 PSI (17 BAR)

Maximum Operating Temperature ................................................................................. 160OF (71 C)Pump Motor

Model 3.0 ..............................................................................½ HP (0.4 kW), 12 VDC (Standard)½ HP (0.4 kW), 24 VDC (Optional)

Model 3.3 and Model 5.0.......................................................¾ HP (0.5 kW), 12 VDC (Standard)¾ HP (0.5 kW), 24 VDC (Optional)

Operating Ampere Draw ...................................................................................................... 30 AMPSMaximum Ampere Draw

Model 3.0 ....................................................................................................................... 40 AMPSModel 3.3 and Model 5.0................................................................................................ 60 AMPS

2.58 IN.(66 MM)

Ι-7



Hale FoamMaster Installation Envelope Dimensions Configured with Optional ADT

6.02 IN.(153 MM)

3.02 IN.(77 MM)

8.95 IN.(227 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


MODEL 5.0: 24.74 IN. (628 MM)MODEL 3.3 & MODEL 3.0: 24.94 IN. (622 MM)MODEL 5.0: 23.70 IN. (602 MM)MODEL 3.3 & MODEL 3.0: 23.45 IN. (596 MM)MODEL 5.0: 21.88 IN. (555 MM)MODEL 3.3 & MODEL 3.0: 21.63 IN. (549 MM)MODEL 5.0: 20.63 IN. (524 MM)MODEL 3.3 & MODEL 3.0: 20.38 IN. (518 MM)


BYPASS HANDLE: BYPASS POSITION

BYPASS HANDLE: INJECT POSITION

INJECT PORT: ½ INCH NPT

BYPASS PORT: ½ INCH NPT

6.20 IN.(157 MM)

3.70 IN.(94 MM)

TANK A CONNECTION¾ INCH I.D. HOSE

4.76 IN.(121 MM)



SYSTEM CONFIGURATION

Hale FoamMaster System Model(Model 3.0, Model 3.3 or Model 5.0)

All Hale FoamMaster sytems include: Foam Pump/Motor Assembly, Control Unit, ControlCable and Check Valve/Injector Fitting

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

Control Unit

6-Pin Control Cable16.5 Feet (Recommended) (P/N 013-2020-05-0)

6.5 Feet (Available) (P/N 013-2020-02-0)

Check Valve/Injector Fitting

LEDOMRETSAMMAOFTRAP

REBMUNROTOMCDV21/W0.5RETSAMMAOF 0-51-0313-105

ROTOMCDV42/W0.5RETSAMMAOF 0-42-0313-105





Ι-9



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 101-1630-07-0)

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)



Foam Concentrate Strainers

FS-15 STRAINER(P/N 510-0150-00-0)

(¾ Inch NPT Threads. Use With Class Aand thin Class B Foam Concentrates)

FS-25 STRAINER(P/N 510-0180-00-0)

(1 Inch NPT Threads. Use With Class Aand Class B Foam Concentrates)

In-Line Strainer/Valve Assembly(P/N 510-0190-00-0)

(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 101-1630-12-0)

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

MST Wiring Harness Extension72 inches (1829 mm) long

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

Ι-11



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)



FlowsensorsEach Hale Foammaster System Requires at Least One Flowsensor to Operate. Flowsensorsmust be Selected Based on the Minimum and Maximum Water Flow in the Foam CapableDischarge. Following is a List of HPF Flowsensor Models, Pipe Size and Rated FlowRange:

HPF Flowsensor

US PIPE THREADED FLOWSENS

MODEL PART NUMBER THREADS VICTHPF15 538-1600-15-0 1-1/2 NPT 2-HPF20 538-1600-20-0 2 NPTHPF25 538-1600-25-0 2-1/2 NPT 3-HPF30 538-1600-30-0 3 NPTHPF40 538-1600-40-0 4 NPT

ISO METRIC FLOWSENSOR

MODEL PART NUMBER THREADS VICTHPF15 ISO 538-1600-16-0 228/1-G1-1/2(ISO) 2-HPF20 ISO 538-1600-21-0 228/1-G2(ISO)HPF25 ISO 538-1600-26-0 228/1-G2-1/2(ISO) 3-HPF30 ISO 538-1600-31-0 228/1-G3(ISO)HPF40 ISO 538-1600-41-0 228/1-G4(ISO)

4-Pin Flowsensor Cable16.5 Feet (Recommended) (P/N 013-2010-05-0)

6.5 Feet (Available) (P/N 013-2010-02-0)

Ι-13



Flowsensor Installation Dimensions

A

B

C

D

E

Minimum of 4 inches (102 mm)required above flowsensor teefor sensor removal and service.

FPHLEDOMREBMUN

ASDAERHT

BCILUATCIV

CEDISTUORETEMAID

DHTGNEL

ETHGIEH

51FPH TPN2/1-1 2/1-2 )MM37(.NI88.2 )MM411(.NI05.4 )MM901(.NI03.5

02FPH TPN2 3 )MM98(.NI05.3 )MM411(.NI05.4 )MM611(.NI55.5

52FPH TPN2/1-2 2/1-3 )MM201(.NI00.4 )MM411(.NI05.4 )MM121(.NI57.5



OSI51FPH OSI2/1-1 2/1-2 )MM37(.NI88.2 )MM411(.NI05.4 )MM601(.NI91.5

OSI02FPH OSI2 3 )MM98(.NI05.3 )MM411(.NI05.4 )MM211(.NI24.5

OSI52FPH OSI2/1-2 2/1-3 )MM201(.NI00.4 )MM411(.NI05.4 )MM711(.NI16.5





Foam Discharge Multiplexing Display Unit (Including Pressure Transducer)(P/N 200-2550-00-0)

(Required Component When Number of Flowsensors is Greater Than One)(When Multiplexing Units are Installed a FoamMaster Power Filter Kit (P/N 546-1870-00-0)

Must be Installed)

Pressure Transducer6-Pin Pressure Transducer Cable

16.5 Feet (Recommended) (P/N 013-2020-05-0)6.5 Feet (Available) (P/N 013-2020-02-0)

Foam Discharge Multiplexing Display Unit

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

4-Pin Remote Activation Switch Cable33 Feet (Recommended) (P/N 013-2010-10-0)

16.5 Feet (Available) (P/N 013-2010-05-0)6.5 Feet (Available) (P/N 013-2010-02-0)

Ι-15



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

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.

Maxi Manifold(P/N 178-0420-00-0)

Additional Components

INLET

OUTLET

FOAMINJECTION

OUTLET

OUTLET

OUTLETFOAM

INJECTION115 FLANGE

CONNECTIONS(EACH SIDE)

2433D FLANGECONNECTIONS3 INCH NPT or 4 INCH

VICTAULIC INLETCONNECTION

DRAINCONNECTION

SDAERHT REBMUNTRAP

TPNHCNI3 0-00-0800-511

TPNHCNI2/1-2 0-00-0700-511

TPNHCNI2 0-00-0600-511

KNALB 0-00-0500-511

SDAERHT REBMUNTRAP

TPNHCNI4 0-00-0400-511

TPNHCNI3 0-00-0300-511

TPNHCNI2/1-2 0-00-0200-511

KNALB 0-00-0100-511



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

115 flange inlet with 3 inch Victaulic outlet.

Flange Gaskets

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

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

Additional Components


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.

Ι-17



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

CONTROLUNIT

DISTRIBUTIONBOX

FLOWSENSORCORDSET

BYPASSVALVE

FOAMINJECTION

HOSE

BYPASSHOSE

WATERWAYCHECKVALVE

IN-LINE FOAM STRAINER/VALVE ASSEMBLY

CONTROLCORDSET

WATERWAYCHECKVALVE

HALEFOAMMASTER

HPFFLOWSENSOR

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



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

FOAMTANK

FOAM TANKDRAINVALVE

MSTSELECTOR

VALVE




FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVEWATERWAY

CHECKVALVEFIRE

PUMP

FOAM PUMP ANDMOTOR

ASSEMBLY

CONTROLCORDSET


CONTROLUNITFLUSHING

WATER SUPPLY

CHECK VALVEINJECTOR

FITTING

HALEFOAMMASTER

HPFFLOWSENSOR


Ι-19



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


CHECK VALVEINJECTOR

FITTING

HALEFOAMMASTER

HPFFLOWSENSOR




Figure 1-3. Hale FoamMaster System Layout with Single Foam Concentrate Tank, MSTand FS Series Strainer




FOAMTANK B

FOAMTANK A

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

MDT ΙΙΙΙΙΙΙΙΙΙSELECTOR

VALVE






FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE


CHECKVALVEFIRE

PUMP

FOAM PUMP ANDMOTOR

ASSEMBLY

CONTROLCORDSET


CONTROLUNIT

FLUSHINGWATER SUPPLY CHECK VALVE

INJECTORFITTING

HALEFOAMMASTER

HPFFLOWSENSOR



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

Ι-21



FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLY

CONTROLCORDSET



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


VALVE

CONTROLUNIT


INJECTORFITTING

HALEFOAMMASTER

HPFFLOWSENSOR






Figure 1-5. Hale FoamMaster System Layout with Dual Foam Concentrate Tanks, MDT ΙΙand FS Series Strainer Assembly



FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE

WATERWAYCHECKVALVE

WATERWAYCHECKVALVEFIRE

PUMP

FOAM PUMPWITH ADT

CONTROLCORDSET


ADTSELECTOR

SWITCH ANDINDICATOR

LIGHTS

CONTROLUNIT


INJECTOR FITTING

HALEFOAMMASTER

HPFFLOWSENSOR


FOAMTANK B

FOAMTANK A

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE








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

Ι-23



FLOWSENSORCORDSET

DISTRIBUTIONBOX

BYPASSVALVE

BYPASSHOSE

FOAMINJECTION

HOSE


CHECKVALVE

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

LIGHTS

CONTROLUNIT


CHECK VALVEINJECTOR

FITTING

HALEFOAMMASTER

HPFFLOWSENSOR

BOTTOM MOUNTFOAM TANK LOWLEVEL SENSOR

OPTION



BOTTOM MOUNTFOAM TANK LOWLEVEL SENSOR

OPTION



Figure 1-7. Hale FoamMaster System Layout with Dual Foam Concentrate Tanks, ADTand FS Series Strainer Assemblies



SYSTEM



SECTION IIINSTALLATION

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

ΙΙ -1


Section ΙΙΙΙΙΙΙΙΙΙ : Installation




















ΙΙ -2























ΙΙ -3



APPARATUS INSTALLATION PLANNINGFS15 or FS25 panel mounted foamstrainerADT operating switch and indicator lights(ADT valve is integral part of foampump)Manual dual tank (MDT ΙΙ) selector valveManual single tank (MST) selector valveFoam discharge multiplexing displayunitsAdditional HPF flowsensorsLine pressure transducersMini or Maxi ManifoldsFlanged elbowsFoam tank(s)Remote activation switch

IMPORTANT: When determining thelocations of Hale FoamMastercomponents 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. Themotor and electrical components aredesigned to withstand the harshenvironment encountered in an emergencyapparatus environment.

Differences in apparatus plumbing andfoam system configuration make itimpractical to show exactly how each HaleFoamMaster system is installed on aparticular apparatus. The informationcontained in this section, however, willapply to most situations and should be usedwhen designing and installing a HaleFoamMaster system. System plumbing andelectrical diagrams are provided at the endof this installation section to assist theapparatus manufacturer with installation ofthe Hale FoamMaster 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 FoamMaster and provide the bestsystem performance. Use of therecommended materials and specifiedparts will ensure a virtually maintenancefree installation.

The Hale FoamMaster system is suppliedwith six major components that must belocated on the apparatus. The majorcomponents of the Hale FoamMastersystem are:

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

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

ΙΙ -4



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 suctionconnections, 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 foam

pump 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.

ΙΙ -5



INSTALLER SUPPLIED COMPONENTRECOMMENDATIONS

Due to the many differences in apparatusconfiguration and apparatus designrequirements the Hale FoamMaster 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 FoamMastersystems 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.

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 foamconcentrate 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.

ΙΙ -6



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 tobe used.

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 VALVESCheck 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 FoamMasterfoam injection system and relatedcomponents are properly installed therequired check valves are integral parts ofthe component parts.

NFPA standards require a check valve inthe foam concentrate injection line at theinjection point. The foam concentratecheck valve shall have a 4 to 5 PSI (0.28 to0.34 BAR) cracking pressure to preventfoam concentrate siphoning from the foamconcentrate tank due to static headpressure. The check valve shall be rated for500 PSIG (34 BAR) water pump dischargepressure. The Hale P/N 038-1790-00-0Integral Check Valve/Injector fitting, astandard component included with theHale FoamMaster 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 zonebetween 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" style

ΙΙ -7



flanges. 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.

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 FoamMaster MDT ΙΙ or Hale MST mustbe made using ½ inch inside diametertubing and appropriate fittings. The tubingand fittings used must be capable ofwithstanding the maximum fire pumpdischarge pressure (500 PSI (34 BAR)minimum) and should be compatible withfoam concentrates being used in thesystem.

When the Hale ADT, Hale FoamMaster MDTΙΙ or Hale MST is installed a check valve isprovided integral 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 HaleFoamMaster system is ordered with the "notank" option the system installer mustprovide proper hose, shutoff valve, check

valves and connections for flushing waterfor the system to be NFPA compliant.Additionally, when the Hale FoamMaster 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 toprevent 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 7 port drain valve,Model DV7 (Hale P/N 529-5420-00-0) thatprovides individual drains with a singlecontrol to use for applications where asingle point for multiple drains is required. Ifa Hale DV7 drain valve is not used thenindividual drain lines and valves for foamcapable discharge piping arerecommended. Hale type HD individualdrain valves (Hale P/N 538-0600-01-0) (usedwithout tees) are recommended.

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

Primary power must be supplied from themain apparatus battery to the distributionbox on the foam pump and motorassembly. The Hale FoamMaster Model 5.0and Model 3.3 each require minimum 60AMP electrical service and the HaleFoamMaster Model 3.0 requires minimum 40AMP electrical service connected to thedistribution box.

Primary electrical power must be supplieddirectly from the battery or the battery

ΙΙ -8



master disconnect switch or solenoids to theHale FoamMaster. Other electricalcomponents must not be supplied from thiswire. DO NOT connect the primer and HaleFoamMaster to the same power wire.

The toggle switch on the Hale FoamMasterdistribution box should be left in the ONposition at all times. So the HaleFoamMaster system is ready for immediateoperation when the operator places theapparatus in pump mode, and to preventbattery power drain when the apparatus isnot running, the primary power connectionmust be made so power is supplied to theHale FoamMaster when the mainapparatus electrical system is energized.Use of a solenoid with a 200 AMP peak, 100AMP continuous rating is recommended.

With Hale FoamMaster 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. For Hale FoamMaster Model3.0 or cable lengths greater than 6 feet (1.8meters) refer to the following table for therecommended battery cable size for HaleFoamMaster system primary power wiring.When planning cable runs make sure theprimary wires are routed by the shortestmost direct route.

SEZISELBACREWOPYRAMIRPDEDNEMMOCER

0.3ledoM 0.5&3.3sledoM htgneLmumixaM

GWA6 GWA4 sseLro)M8.1(tF6

GWA4 GWA0 )M6.4(tF51ot)M8.1(tF6

GWA0 GWA00 regnoLro)M6.4(tF51

A braided flat ground strap is required forthe ground connection to limit the RFI/EMIinterference encountered with radios,computers or other sensitive electronicequipment. The ground strap should be aminimum of 1-¼ inches (32 mm) wide andbe no longer than 18 inches (457 mm) long.The ground strap must have soldered flat

lug ends with 5/16 inch (8 mm) diameterholes. 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 not the apparatusbody work. Before making groundconnection remove all paint, grease andcoatings from the connection area. Aftermaking connection seal against corrosion.

NOTE: When an inline current shuntammeter is installed on the apparatus orthe Hale FoamMaster is used withMultiplexing Display Units with multiple waterflow meters it is necessary to install aFoamMaster power filter kit (Hale P/N 546-1870-00-0) on the Hale FoamMaster foampump.

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 FoamMaster modelsbased on NFPA requirements for flammableliquid (Class B) fire suppression.

RETSAMMAOFLEDOM

MAOFDEDNEMMOCERYTICAPACKNAT

0.5LEDOM )sretiL973(.LAG001



ΙΙ -9



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 2-1).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 2-2 and 2-3 provide themounting envelope dimensions for the HaleFoamMaster foam pump and motorassembly.

Position the foam pump so the ON/OFFswitch and bypass valve are easilyaccessible. When the Hale FoamMastersystem 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 FoamMaster systemis ordered with the ADT option, theoperating knob can be removed from thebypass valve actuator and an extensionrod can be installed to permit remoteoperation. In either instance the foampump and motor assembly must be locatedto permit proper operation of the bypassvalve.

CORRECT

INCORRECT

INCORRECTFigure 2-1. Hale FoamMaster Installation

ΙΙ -10



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 2-4.

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.

Figure 2-2. Hale FoamMaster Installation Envelope Dimensions

9.43 IN.(240 MM)

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)

ΙΙ -11



Figure 2-4. Hale FoamMaster 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 2-3. Hale FoamMaster Installation Envelope Dimensions with Optional ADT

6.02 IN.(153 MM)

3.02 IN.(77 MM)

8.95 IN.(227 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


MODEL 5.0: 24.74 IN. (628 MM)MODEL 3.3 & MODEL 3.0: 24.94 IN. (622 MM)MODEL 5.0: 23.70 IN. (602 MM)MODEL 3.3 & MODEL 3.0: 23.45 IN. (596 MM)MODEL 5.0: 21.88 IN. (555 MM)MODEL 3.3 & MODEL 3.0: 21.63 IN. (549 MM)MODEL 5.0: 20.63 IN. (524 MM)MODEL 3.3 & MODEL 3.0: 20.38 IN. (518 MM)


BYPASS HANDLE: BYPASS POSITION

BYPASS HANDLE: INJECT POSITION

INJECT PORT: ½ INCH NPT

BYPASS PORT: ½ INCH NPT

6.20 IN.(157 MM)

3.70 IN.(94 MM)

TANK A CONNECTION¾ INCH I.D. HOSE

4.76 IN.(121 MM)

ΙΙ -12



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 and maximanifolds, etc. can simplify installation ofwater and foam solution discharge piping.The arrangement shown in figure 2-5

Hale FoamMaster System plumbing diagrams are located at the end of this manualsection. The diagrams provide recommended guidelines for the installation of systemcomponents that handle water, foam concentrate and foam solution. The sequence inwhich the plumbing installation is completed depends on the individual installation.

PLUMBING COMPONENT INSTALLATION

provides accurate proportioning across awide range for up to four discharges fromthe mini manifold. The dual check valvearrangement helps to ensure that no foamconcentrate will contaminate the pumpwater. The Hale mini manifold provides a 1inch NPT tap for installation of the checkvalve/injector fitting. The Hale mini manifoldand elbow components use 4-3/8 inchdiameter bolt circles and minimizefabrication and pipe work. After installationof the plumbing is complete make sure allpipes, hoses and tubes are supported usingthe best industry practices.

HALE HPF 25FLOWSENSOR

HALE MINI MANIFOLDPROVIDES 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 2-5. 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

ΙΙ -13



in figure 2-7. DO NOT let the flowsensorsrotate more than 85o in either direction forproper operation.

When selecting flowsensors it is important toconsider the minimum and maximum flowrequirements during operation, not thepiping size being used as one flowsensorMAY NOT cover the entire range of systemflows. Refer to the flowsensor selectionchart in Section Ι of this manual for properflowsensor sizing and installation dimensions.

When a single flowsensor is installed in theHale FoamMaster system it should beinstalled in the piping before the foamconcentrate injection point.

Some applications will require installation ofa Hale mini or maxi manifold to provide acommon foam concentrate injection pointand the use of multiple flowsensors withHale foam discharge multiplexing displayunits.

Other applications may be designed to usea single flowsensor due to space restrictionson the apparatus. In this instance theflowsensor selected can be one pipe sizesmaller than the piping run (4 inch to 3 inch,

Figure 2-6 shows a suggested installationarrangement using Hale 4 inch checkvalves, Hale 2433 flanges and 4 inch pipe.A maxi manifold is available from Hale toprovide multiple discharges with a commonfoam injection point using Hale 2433 boltpattern flanges. The discharges availableare similar to those shown for the minimanifold.

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.

FLOWSENSOR(S)Hale FoamMaster HPF flowsensors arespecially designed to make inspection andmaintenance of the flow sensor easy. Theflowsensors are installed in the foamcapable discharge piping of theapparatus. In horizontal piping runs, theflowsensors should be mounted as close toupright as possible within the range shown

Figure 2-6. Typical 4 Inch Check Valve Installation on Midship Pump

ΙΙ -14



3 inch to 2-½ inch, 2-½ inch to 2 inch or 2inch to 1-½ inch) to provide for betteraccuracy at low flow rates. Always refer tothe flowsensor selection chart in Section Ι ofthis manual for proper flowsensor sizing andinstallation dimensions. Selection of thenext smaller flowsensor permits reducing thestraight pipe run the required distance priorto the flowsensor inlet then increasing thepipe size on the flowsensor outlet. In theshort length of reduced pipe pressure losswill be minimal and there will be minimalpressure loss through elbows and fittings.Figure 2-8 shows a typical reduced pipingrun installation.

As an alternative to using reduced pipesize, Hale HPF flowsensor tees are machinedwith a ring that accepts Victaulic typeconnection fittings for installation.

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 FoamMaster system.

a. A minimum 5 times the pipe diameterof straight run pipe without any fittings isnecessary prior to the flowsensor tee(see figure 2-9). Minimum requiredstraight pipe run:

eziSepiPdednemmoceRmuminiM

epiPnuRthgiartS

)mm83(.ni½-1 )mm191(.ni½-7

)mm05(.ni2 )mm452(.ni01

)mm46(.ni½-2 )mm713(.ni½-21

)mm67(.ni3 )mm183(.ni51

)mm201(.ni4 )mm805(.ni02

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

Figure 2-8. Typical Reduced Flowsensor Piping Arrangement

Figure 2-7. 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

ΙΙ -15



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

With the use of Hale foam dischargemultiplexing display units, 2 to 8 flowsensorsand pressure transducers may bemonitored simultaneously. The pressuretransducers enable replacement of linegauges on foam capable dischargeoutlets. A single injection point that willsupply foam concentrate to all foamcapable discharge outlets is required asshown in figure 2-10. Manifolds areavailable from Hale Products Inc. (Minimanifold; Hale P/N 178-0320-02-0 or Maximanifold; Hale P/N 178-0420-00-0) for this

Figure 2-10. Typical Piping Arrangement with Multiple Flowsensors

Figure 2-9. 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

FOAM CONCENTRATEINJECTION HOSE

FROM HALEFOAMMASTER

WATERFROMPUMP

HALE HPFSERIES

FLOWSENSOR

FOAMSOLUTION

DISCHARGE(S)

HALE MINI MANIFOLD, MAXIMANIFOLD or INSTALLERFABRICATED MANIFOLD

HALE HPFSERIES

FLOWSENSOR


HALE HPFSERIES

FLOWSENSOR


HALE HPFSERIES

FLOWSENSOR


FOAM INJECTION CHECKVALVE/INJECTOR FITTING

WATERWAYCHECK VALVE

PRESSURETRANSDUCER

DISCHARGEVALVE

PRESSURETRANSDUCER

DISCHARGEVALVE

PRESSURETRANSDUCER

DISCHARGEVALVE

PRESSURETRANSDUCERDISCHARGE

VALVE

➨➨➨➨➨

➪➪➪➪➪

➨➨➨➨➨

➧➧➧➧➧

➩➩➩➩➩

ΙΙ -16



purpose, or a manifold can be designedand constructed by the system installer.

CAUTION: The Hale HPF flowsensor isassembled and tested at the factory.Removal of the sensor from the tee is notnecessary or recommended forinstallation in the system.

It is not necessary to remove the sensor fromthe flowsensor tee for installation. If removalis necessary refer to figure 2-11 for guidancein disassembly of the flowsensor. Afterinstallation of the flowsensor tee is completethe sensor must be inserted back into thetee if it was removed. Make sure the two o-rings are in the grooves on the sensor

before inserting into the tee. After thesensor is seated in the flowsensor tee it mustbe locked in place using the locking pinand locknut provided. The locknut must betightened handtight only. (See figure 2-11)

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 II 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 FoamMaster 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. Flush waterthread connections on the ADT are ½ inchNPT and on the Hale MDT ΙΙ and Hale MSTthey are ¼ inch NPT. The system installermust provide proper fittings for theseconnections.

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 are

Figure 2-11. Flowsensor Sensor Service

WATER FLOW DIRECTION

➭➭➭➭➭

FLOWSENSORTEE

LOCKINGPIN

O-RINGS

SENSOR

GROUND WIRECONNECTION

TERMINAL ANDSCREW

LOCKNUT

ΙΙ -17



clean before making final connection tofoam pump. If necessary flush tank andhoses prior to making connection.

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 1inch NPT female threaded ports. Fittings aresupplied for connection of ¾ inch (19 mm)or 1 inch (25 mm) inside diameter hosedepending on the viscosity of foamconcentrates used. (See figure 2-12)Generally ¾ inch inside diameter hose willbe used for Class A foam and 1 inch insidediameter hose will be used for Class Bfoams. A bracket is included with the in-linestrainer/valve assembly to permit installationon the apparatus.

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 apparatus

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

STRAINER BRACKET OUTLINESHOWN FOR CLARITY

3-1/8 IN.(79 MM)

2-2132 IN.(67 MM)

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

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

¾ INCH NPT X ¾ INCH HOSEFITTING

(Use on each end for Class Afoam concentrates)

1 INCH NPT X ¾ INCH NPTBUSHING

(Use on each end for Class Afoam concentrates)

1 INCH NPT X 1 INCH HOSEFITTING

(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

ΙΙ -18



that 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 securethe 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.

When using class A or low viscosity classB foam concentrates use the 1 inch NPTx ¾ inch NPT bushings and the ¾ inchNPT x ¾ inch hose fittings in each end ofthe strainer/valve assembly.

Class B foam concentrates generallyrequire the use of the 1 inch NPT x 1 inchhose 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 valveend. Wetting the ends of the hose andfittings will help ease installation on thehose fittings.

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 theinlet of the Hale MDT ΙΙ , Hale MST orfoam concentrate pump.

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 sure

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

ΙΙ -19



the 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, markholes 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 be

capable 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. Install thefittings into the strainer and tightensecurely.

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.

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)


(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

ΙΙ -20



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

CORRECT

INCORRECT

CHECK VALVE/INJECTOR FITTINGBELOW HORIZONTAL PLANE

Figure 2-16. Check Valve/Injector FittingPosition

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. If necessary flush tank andhoses prior to making connection.

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

CHECK VALVE/INJECTOR FITTINGThe Hale check valve/injector fittingsupplied with the Hale FoamMaster 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 FoamMastersystem does not permit a separate injectionpoint for each foam capable discharge.Even though multiple flowsensors andpressure sensors are installed on a particularsystem, the check valve/injector fitting mustbe installed before these components atthe inlet to their common manifold (refer tofigure 2-10).

The check valve/injector fitting has 1 inchNPT threads on the outside to fit into the 1inch NPT threaded connection on the Halemini manifold, maxi manifold, a pipe tee ora 1 inch NPT weld fitting installed in thedischarge piping of the fire pump (seefigure 2-17). The inlet connection of thecheck valve/injector fitting has ½ inch NPTfemale threads.

FOAM CONCENTRATE INJECTION HOSEConnect hose from the foam pump injectport (see figure 2-19) to the inlet of thecheck valve injector fitting. The hose andfittings from the INJECT port to the checkvalve injector fitting should have minimum

CHECK VALVE/INJECTOR FITTINGABOVE HORIZONTAL PLANE

ΙΙ -21



½ inch (13 mm) inside diameter and berated 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 bypass valve ismounted on the discharge of the foampump when the ADT option is not installed.The bypass handle shall be accessible by

the pump operator during normaloperations.

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 2-19) 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 to

Figure 2-19. 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 FOAMMASTER WITH NO TANK,MST OR MDT ΙΙ OPTION HALE FOAMMASTER WITH ADT OPTION

Figure 2-18. Injector Fitting Placement for Multiple Discharges with Single Flowsensor

FOAMCONCENTRATE

INJECTION HOSE

WATERFROMPUMP


HALE MINI MANIFOLD, MAXIMANIFOLD or INSTALLERFABRICATED MANIFOLD

HALE HPFSERIES

FLOWSENSOR

FOAMSOLUTION

DISCHARGE(S)FOAM INJECTION

CHECK VALVE/INJECTOR FITTING

WATERWAYCHECK VALVE

MINIMUM 5X THEPIPE DIAMETER

BEFOREFLOWSENSOR TEE

FOAMSOLUTION

DISCHARGE(S)


FLUSHING WATERPORT ½ INCH NPT

ΙΙ -22



each 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 thefoam 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 2-20.

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 2-21

After mounting the placard assembly installthe air hoses from the ADT to the placardassembly. Make sure proper connectionsare made at the placard assembly asindicated in figure 2-22. 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 canbe 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.

Figure 2-20. Bypass Valve Assembly

ACORN NUT

BYPASS HOSECONNECTION

INJECT HOSECONNECTION

PLACARD

CASTBOSSES

HANDLETANG

PLACARDSCREWS

HANDLE

ΙΙ -23



Figure 2-21. 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 -24



Figure 2-22. 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 -25



SYSTEM PLUMBING DIAGRAMSThe following pages contain Hale FoamMaster 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 HaleFoamMaster system. These diagrams are intended as guidelines to assist the systeminstaller with selection of hoses and fittings along with the connections required.

ΙΙ -26



Hale FoamMaster System Plumbing Diagram with Single Foam Concentrate Tank

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

HALEFOAMMASTER

HPFFLOWSENSOR

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 FoamMaster 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

ΙΙ -27



Hale FoamMaster System Plumbing Diagram with Single Foam Concentrate Tank, MSTand In-line Strainer/Valve Assembly

FOAMTANK

FOAM TANKDRAINVALVE

BYPASSVALVE


CHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLY


CHECK VALVEINJECTOR

FITTING

HALEFOAMMASTER

HPFFLOWSENSOR





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

ΙΙ -28



Hale FoamMaster System Plumbing Diagram with Single Foam Concentrate Tank, MSTand FS 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

HALEFOAMMASTER

HPFFLOWSENSOR




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

ΙΙ -29



FOAMTANK B

FOAMTANK A

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

BYPASSVALVE


CHECKVALVE

FIREPUMP

FOAM PUMP ANDMOTOR

ASSEMBLY


CHECK VALVEINJECTOR

FITTING

HALEFOAMMASTER

HPFFLOWSENSOR

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

MDT ΙΙΙΙΙΙΙΙΙΙ 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)



ΙΙ -30



WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP


HALEFOAMMASTER

HPFFLOWSENSOR

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

FOAMTANK B

FOAMTANK A

FOAM TANKSHUTOFF

VALVEFOAM TANK

DRAINVALVE

FOAM TANKDRAINVALVE

FOAM TANKSHUTOFF

VALVE

BYPASSVALVE

FOAM PUMP ANDMOTOR

ASSEMBLY CHECK VALVEINJECTOR

FITTING

MDT ΙΙΙΙΙΙΙΙΙΙ 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

ΙΙ -31




CHECKVALVE

FIREPUMP


HALEFOAMMASTER

HPFFLOWSENSOR

Hale FoamMaster System Plumbing Diagram with Dual Foam Concentrate Tanks, ADTand In-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)



ΙΙ -32



Hale FoamMaster System Plumbing Diagram with Dual Foam Concentrate Tanks, ADTand FS Series Strainer Assemblies

WATERWAYCHECKVALVE

WATERWAYCHECKVALVE

FIREPUMP


HALEFOAMMASTER

HPFFLOWSENSOR

FOAMTANK B

FOAMTANK A

FOAM TANKSHUTOFF

VALVE

FOAM TANKDRAINVALVE

FOAM TANKDRAINVALVE

FOAM TANKSHUTOFF

VALVE

FOAM PUMP ANDMOTOR

ASSEMBLY

CHECK VALVEINJECTOR

FITTING






and 50 PSI (3 BAR)


AT 500 PSI (34 BAR)

½ INCH NPTFLUSH HOSECONNECTION



and 50 PSI (3 BAR)

¾ INCH NPT x ¾INCH HOSE

FITTINGS FORFS15 STRAINER

1 INCH NPT x¾ INCH HOSEFITTINGS FOR

FS25STRAINER



ΙΙ -33



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 FoamMaster system is designed to beinstalled with a minimum of electricalconnections. Complete electricallyshielded cables are provided with eachHale FoamMaster 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 HaleFoamMaster distribution box.

• The cables provided with each HaleFoamMaster 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 FoamMaster systems are designedfor use on direct current, negativeground apparatus electrical systems only.

• Do not mount radio transmitter ortransmitter cables in direct or closecontact with the Hale FoamMaster 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 HaleFoamMaster 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 HaleFoamMaster 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 servicable parts insideHale FoamMaster system electrical/electronic components. Opening ofthese components (distribution box,control unit, foam discharge multiplexingdisplay unit) will void warranty.

• When an inline current shunt ammeter isinstalled on the apparatus or the HaleFoamMaster is used with MultiplexingDisplay Units with multiple water flowmeters it is necessary to install aFoamMaster power filter kit (Hale P/N546-1870-00-0) on the Hale FoamMasterfoam pump.

ΙΙ -34



CONTROL UNITThe control unit mounts in the operatorpanel of the apparatus. The cutoutrequired in the operator panel is a 3-¾ inch(95 mm) diameter hole. The display issecured with four #10 socket head screws inthe four holes in the face (See figure 2-23 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, connect the 6 pin control cable fromthe male distribution box connection (figure2-24) to the 6 pin female connector on theback of the control unit (figure 2-25). Adecal on the distribution box identifies eachcable connection (see figure 2-24).

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.

FLOWSENSOR CONNECTIONSIf a single Hale FoamMaster paddlewheel

type flowsensor is used, a cable is suppliedwhich connects from the 4 pin connector(refer to figure 2-11) or pigtail on the sensorto the male 4 pin connector on the controlunit (see figure 2-25).

FOAM DISCHARGE MULTIPLEXINGDISPLAY UNITSSee foam discharge multiplexing systemmanual (P/N 029-0020-36-0) for multipleHale FoamMaster Flowsensor installations.Figure 2-26 shows the connection of theflowsensors, pressure transducers anddisplay unit with the control unit forreference only.

NOTE: When an inline current shuntammeter is installed on the apparatus orthe Hale FoamMaster is used withMultiplexing Display Units with multiplewater flow meters it is necessary to installa FoamMaster power filter kit (Hale P/N546-1870-00-0) on the Hale FoamMasterfoam pump.

FOAM TANK LOW LEVEL SENSORINSTALLATIONThe foam tank low tank level sensor(s) mustbe installed and wired to monitor foamconcentrate level. Mount a low tank level

Figure 2-23. Control Unit Mounting Dimensions



(4 PLACES)

0.63 IN.(16 MM)

4.28 IN.(109 MM)

1.75 IN.(44 MM)

1.75 IN.(44 MM)

3.50 IN.(89 MM)

4.28 IN.(109 MM)

3.50 IN.(89 MM)

7.00 IN. (178 MM)CLEARANCE BEHIND OPERATOR PANEL

OPERATORPANEL

ΙΙ -35



sensor in each foam tank as follows. Referto figure 2-27 for low tank level sensormounting options.

CAUTION: Foam tank low level sensorsmust be utilized to protect the HaleFoamMaster from dry running. Failure touse low level sensors with the HaleFoamMaster 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 1Figure 2-25. Control Unit Cable

Connections

INPUT FROM HALE HPF FLOWSENSOR,FOAM DISCHARGE DISPLAY OR CAFSPRO

SAFETY INTERLOCK(4-PIN MALE)

REMOTE ON/OFFOPERATOR

(4-PIN FEMALE)

CONTROL CABLEFROM DISTRIBUTION

BOX(6-PIN FEMALE)

POWERINDICATOR

LED

Figure 2-24. 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 ΙΙΙΙΙΙΙΙΙΙ 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)

ΙΙ -36



inch NPT bushing and a bulkhead fittingwith 1 inch FNPT threads (see figure 2-28).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 foamconcentrate level is not restored theHale FoamMaster system will shut down.When locating the side mount low tanklevel sensor on the foam tank sufficient

Figure 2-27. Foam Tank Low Level SensorMounting Options

BOTTOM MOUNTLOW LEVEL

SENSOR OPTION

SIDE MOUNTLOW LEVEL

SENSOROPTION

TOP MOUNT LOWLEVEL SENSOR

OPTION

TYPICALFOAM TANK

Figure 2-26. Multiple Flowsensor Connections with Hale Foam Discharge MultiplexingDisplay Units

CONTROLUNIT

FOAM DISCHARGE MULTIPLEXING DISPLAY UNITS.2 TO 8 UNITS MAY BE CONNECTED IN SERIES

CONTROL CABLETO HALE

FOAMMASTERDISTRIBUTION BOX

PRESSURETRANSDUCER

PRESSURETRANSDUCER

PRESSURETRANSDUCER

PRESSURETRANSDUCER

HALE HPF SERIESFLOWSENSOR

➨➨➨➨➨ �FOAM SOLUTIONDISCHARGE

DISCHARGESHUTOFF

VALVE

DISCHARGESHUTOFF

VALVE

DISCHARGESHUTOFF

VALVE

DISCHARGESHUTOFF

VALVE







ΙΙ -37



foam concentrate should be present forone minute of operation at rated flow.

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.

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 the

foam 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 2-39. Theflange gasket can also be used as atemplate to mark hole location.

a. Using dimensions in figure 2-29, 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.

b. Determine the approximate length ofthe top mount low tank sensor extensionby measuring from the top of the foamtank at the flange opening to the

Figure 2-28. 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)

ΙΙ -38



Figure 2-30. 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

3/8 FNPT X 5/8 TUBEFITTING

5/8 INCH O.D.STAINLESS TUBE

½ INCH O.D.STAINLESS TUBE

SENSORWIRE

bottom 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.

c. 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.

NOTE: If telescoping section will not getshort enough it can be disassembledand cut. Take care to deburr the endsof the tubes after they are cut. Cut anequal amount from each section oftubing.

IMPORTANT: Use the followingprocedure only if the tube sections aretoo long otherwise proceed to step d.

Refer to figure 2-30, disassemble and cutthe tube sections as follows:

1) Loosen and remove the 3/8 FNPT x5/8 tube fitting and strain relief from thetop of the sensor assembly. Carefully

slide the sensor wire out of the strainrelief gland.

2) Loosen and remove the ¼ FNPT x½ tube fitting and sensor from thebottom of the sensor assembly. DO NOTremove the ½ inch tube from the 5/8 inchtube.

3) Using a tubing cutter, remove therequired length of tube from the end ofeach tube. Deburr the cuts whencomplete.

4) Install a new ½ compressionferrule on the end of the tube. Carefullythread the sensor wire through the tubeassembly and attach the ¼ FNPT x ½

Figure 2-29. 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. ThruHole

0.72 in.(18 mm)

1.44 in.(37 mm)

MINIMUM LENGTHWITHOUT CUTTING TUBESECTIONS 31-½ INCHES

(800 MM)

ΙΙ -39



tube fitting with sensor attached to theend of the tube. Tighten the ½ tubecompression nut.

5) Install a new 5/8 compressionferrule on the end of the tube. Carefullythread the sensor wire through the 3/8

FNPT x 5/8 tube fitting and strain reliefgland. Attach the 3/8 FNPT x 5/8 tubefitting and strain relief to the end of thetube. Tighten the 5/8 tube compressionnut.

6) Slide the flange to the top of the5/8 inch 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.

d. 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.

e. 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.

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

LOW LEVEL SENSOR WIRINGCAUTION: When extending the low tanksensor wires make sure the splices are

properly 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 2-24). 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.

DUAL FOAM TANK SYSTEMWhen the Hale FoamMaster system isinstalled using a Hale ADT or Hale MDT ΙΙconnect the low tank level sensors using thefollowing procedure (refer to figure 2-31):

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. Where

ΙΙ -40



two 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 FoamMastersystem 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 thecenter 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.

GROUND AND PRIMARY POWERCONNECTIONS

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 sealantprovided.

GROUND CONNECTIONBe sure the Hale FoamMaster 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 HaleFoamMaster system. (See figure 2-24)When making the ground strap connectionsmake sure lugs are attached to the strapends for trouble 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 FoamMasterModel 3.3 and Model 5.0 require 60 AMPminimum current. The Hale FoamMasterModel 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.

Figure 2-31. Low Tank Sensor A-BSwitchbox Connections

TANK BTERMINAL

COMMONTERMINAL

TANK ATERMINAL

A-B SWITCHBOX MOUNTED ONFOAM PUMP

ΙΙ -41



Table 2-1

SEZISELBACREWOPYRAMIRPDEDNEMMOCER

0.3ledoM 0.5&3.3sledoM htgneLmumixaM

GWA6 GWA4 sseLro)M8.1(tF6

GWA4 GWA0 )M6.4(tF51ot)M8.1(tF6

GWA0 GWA00 regnoLro)M6.4(tF51

RFI/EMIElectrically shielded cables for control unit,flowsensor, foam discharge multiplexingdisplay units and pressure transducers areprovided with the Hale FoamMaster 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 HaleFoamMaster system. Additionally, makesure radio cables and hardware are notlocated in the immediate area where HaleFoamMaster 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 ground

strap at least ¼ inch (6 mm) wide from theflowsensor tee to the apparatus frame toensure 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 2-32)

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:

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 panelcutout 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.

Figure 2-32. Extra Cable Storage

DON'TMODULAR CABLE

MODULAR CABLE

DOWIRE TIES

ΙΙ -42



Figure 2-33. Remote Activation Switch Installation Dimensions

4.50 IN. (114 MM) MINIMUMCLEARANCE FOR CABLE

3.22 IN. (82 MM)

2.72 IN.(69 MM)

2.00 IN.(51 MM)

3.06 IN.(78 MM)

1.53 IN.(39 MM)

2.50 IN.(64 MM)1.25 IN.

(32 MM)

0.63 IN.(16 MM)

1.51 IN.(38 MM)

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

1.00 IN.(25 MM)

MOUNTINGPANEL

4. Connect the remote activationswitch cable from the connector on thecontrol unit (see figure 2-25) to theconnector on the back of the remoteactivation switch.

ΙΙ -43



HALE FOAMMASTER 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 FOAMMASTER SYSTEM (NO TANK OPTION)

FLOWSENSORCABLE

CONTROLCABLE

LOW TANK LEVEL SENSORUSE MINIMUM 16 AWG TYPE


CONTROLUNIT

HALE FOAMMASTER 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.






ΙΙ -44



HALE FOAMMASTER SYSTEM WITH MDT ΙΙ

HALE FOAMMASTER SYSTEM WITH ADT

FLOWSENSORCABLE

CONTROLCABLE


SXL OR GXL (SAE J1128)WIRE

CONTROLUNIT

ADT PANELPLACARD LIGHT

CONNECTION

FLOWSENSORCABLE

CONTROLCABLE



CONTROLUNIT

MDT ΙΙΙΙΙΙΙΙΙΙ WIRINGHARNESS

OPTIONALMDT ΙΙΙΙΙΙΙΙΙΙ WIRING

HARNESS EXTENSION


HALE FOAMMASTER SYSTEM ELECTRICAL DIAGRAMS(Continued)











ΙΙ -45



8

START-UP CHECKLISTBefore energizing the apparatus and Hale FoamMaster 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 or foam discharge multiplexing

display 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 FoamMaster 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(s) 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.

ΙΙ -46



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, ON and all bargraphLEDs will light along with "88888" for severalseconds. "HALE" will then appear forseveral seconds while the system checksitself followed by the default display. If theHale FoamMaster system is installed with asingle flowsensor the default display is zeroon the digital readout (if no water is flowing)and FLOW LED (See figure 2-33). When theHale FoamMaster is installed using multipleflowsensors and foam dischargemultiplexing display units the default displayis % FOAM. 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 FoamMaster foampump for more than one minute per foamtank. DO NOT attempt to calibrate foampump feedback sensor with other than enduser specified foam concentrate. Makesure the bypass valve is in the BYPASSposition when pumping water with thefoam pump.

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

Figure 2-33. Control Unit Ready Indication

WARM-UP/SYSTEM CHECKING

SYSTEM READY

SYSTEM INSTALLER START-UP

INITIAL POWER-UP

ΙΙ -47



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.

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 onegallon container at the discharge of thebypass hose.

5. Place the system in simulated flowmode by selecting the FLOW display anddepressing RESET (both up � and down� buttons simultaneously). Set simulatedflow value to 100 GPM by pressing up �

Figure 2-34. Simulated Flow Display

or down � button. Display will show “S”at the left most position to indicate thesimulated flow (See figure 2-34).

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.Depress ON button to energize HaleFoamMaster 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 through 8 fortank B.

9. After foam pump operation hasbeen checked with both foam tanks exitsimulated flow mode by selecting theFLOW display and depressing RESET(both up � and down �buttonssimultaneously).

ΙΙ -48



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 FoamMaster systemoperation checks that can beaccomplished at the system installer facility.Foam pump feedback calibration alongwith 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.



SYSTEM



SECTION IIISET-UP AND CALIBRATION

NOTICE: This manual section is used by the installer and end user for setting up and calibratingthe Hale FoamMaster system. This manual section also provides procedures for the end user tochange 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.

ΙΙΙ -1


Section ΙΙΙΙΙΙΙΙΙΙΙΙΙΙΙ : Set-up and Calibration




















ΙΙΙ -2























ΙΙΙ -3



INSTALLATION AND DELIVERY CHECKLIST

After the Hale FoamMaster system has been installed the following check list should beused to verify installation and ensure proper system set-up when apparatus is delivered tothe end 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(s) function checked and flowsensor(s) 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 FoamMaster system operation demonstrated to enduser in accordance with manual procedures. (SECTION IV;OPERATING INSTRUCTIONS)

_______ _______ � End user trained in proper operation of Hale FoamMaster 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.

ΙΙΙ -4



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, ON and all bargraphLEDs will light along with "88888" for severalseconds. "HALE" will then appear forseveral seconds while the system checksitself followed by the default display (Seefigure 3-1). If default display does notappear, refer to TROUBLESHOOTING forpossible causes and 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 HaleFoamMaster 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.

3. Place the system in simulated flow modeby selecting the FLOW display and

depressing RESET (both up ��anddown � buttons simultaneously).Increase simulated flow value by

INITIAL END USER SET-UP

Figure 3-1. Control Unit Ready Indication

WARM-UP/SYSTEM CHECKING

SYSTEM READY

INITIAL POWER-UP

ΙΙΙ -5



pressing � button to permit easierpriming (above factory default value of150 GPM). Display will show “S” at theleft most position to indicate thesimulated flow (See figure 3-2).

4. Engage the Hale FoamMaster system bypressing the red ON button. The ONbutton will illuminate to indicate thesystem is on and the bargraph indicateswhether foam concentrate is beingpumped. If no concentrate is flowingthe pump will increase to maximumspeed in an attempt to prime itself. Thepump will run at full speed until afeedback signal is indicated or for 30seconds. If no feedback signal ispresent after 30 seconds the system willshut down and the display will show"noPri" (no prime). Repeat this step onemore time to attempt to prime thepump.

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.

ΙΙΙ -6



Figure 3-3. Calibration Mode Display2. PRESS AND RELEASE

1. PRESSAND HOLD

USER CALIBRATIONThe complete Hale FoamMaster 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 HaleFoamMaster 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 flowsensor(s)and 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 FoamMaster 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 HaleFoamMaster foam system or if differentviscosity foam concentrates are used.

SYSTEM USER CALIBRATION MODESystem user calibration is accomplished byusing the control unit function buttons.

To enter system user calibration mode pressand hold the SELECT DISPLAY button, thensimultaneously press and release the � and

� buttons. The display will show “CALIb”(See figure 3-3) for several seconds followedby "C 0" and FLOW LED. (See figure 3-4)

To exit system user calibration mode andlock the settings press and hold the SELECTDISPLAY button, then simultaneously pressand release the � and � buttons. The word“HALE” will appear for several secondsfollowed by the default display.

FACTORY DEFAULT VALUESDuring calibration it may be desired toreturn the simulated flow rate orconcentrate injection rate(s) to the originalfactory default settings. To return to thefactory default values enter system usercalibration mode as previously described.While calibrating the particular item simplydepress the � and � simultaneously. Thisaction will return the value displayed to thefactory default setting. Proceed withcalibration after performing 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)

ΙΙΙ -7



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 apparatusand delivery to end user.

NOTE: An accurate flow measuringdevice must be used to measure thewater flow when calibrating theflowsensor(s). 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.

If the value requires adjustment do thefollowing:

Enter system user calibration mode usingthe method previously described. Press theSELECT DISPLAY button to illuminate the LEDunder FLOW. The current water flow ratepreceeded by a "C" will be displayed (Seefigure 3-4). Press the � or � button to setthe reading to match the actual flowcalculated from the Pitot gauge reading.Decrease fire pump pressure byapproximately ½ and recalculate waterflow rate. Verify the reading on the controlunit is within 5% of the actual value. Stopthe water flow when the readingadjustments are completed.

To lock the settings, exit system usercalibration mode by pressing and holdingthe SELECT DISPLAY button, then pressingand releasing the � and � buttons. Theword “HALE” will appear for several secondsfollowed by the default display.

FOAM CONCENTRATE INJECTION RATEWhen the Hale FoamMaster 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 system calibration mode. Enter systemuser calibration mode as previouslydescribed.

Use the SELECT DISPLAY button to illuminatethe LED below % FOAM. The display willshow the current default concentrateinjection rate stored in the computermemory for the selected foam concentratetank (see figure 3-5). 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.

Figure 3-4. Flowsensor Calibration Display

ΙΙΙ -8



followed by the default display.

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. Only checkcalibration using actual foamconcentrates. DO NOT use water,training or test foams for feedbackcalibration verification.

Enter system user calibration mode usingthe method previously described. Press theSELECT DISPLAY button to illuminate the LEDbelow TOTAL FOAM on the Control unit. Thecontrol unit display will show " x_xx"indicating the total volume of foamconcentrate pumped during the last

calibration run (See figure 3-6).

Turn the bypass valve handle to the BYPASSposition and place a graduated measurecontainer at the outlet of the bypass hosethat can contain the expected volume offoam concentrate, 5 gallons (19 liters)minimum (figure 3-7).

NOTE: If an accurate calibratedcontainer is not available an accurate

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.

To lock the settings, exit system usercalibration mode by pressing and holdingthe SELECT DISPLAY button, then pressingand releasing the � and � buttons. Theword “HALE” will appear for several seconds

Figure 3-6. Foam Pump FeedbackCalibration Display

Figure 3-5. Foam Concentrate InjectionRate Default Value Set Display

TANK SELECTOR (TANK B)

TANK SELECTOR (TANK A)

ΙΙΙ -9




SIMULATED FLOWThe default Simulated Flow value is factoryset to 150 GPM (568 LPM) and, if necessary,the default value can be adjusted while insystem user calibration mode. Enter systemuser calibration mode using the methodpreviously described. Press the SELECTDISPLAY button until the LED under TOTALFLOW is illuminated. The default simulatedflow rate will be displayed as shown in figure3-8. Adjust the setting by pressing the � or� buttons to set the desired rate, i.e., “S150”.


The above procedures completeverification and adjustment of the system.The Hale FoamMaster system is now readyto be placed in service.

scale can be used to weigh the foamconcentrate pumped. The total volumeof foam concentrate can then becalculated from this weight and thedensity of the foam concentrate fromthe MSDS sheet.

Start the Hale FoamMaster foam pump bypressing the red ON button. The ON buttonwill illuminate and the foam pump willoperate at approximately 2/3 speed topump foam concentrate into the container.The display will show the volume of foamconcentrate pumped. Stop the foampump and measure precisely the amountof 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.

Turn the bypass valve handle back toINJECT position. Figure 3-8. Simulated Flow Calibration

Display

Figure 3-7. Foam Concentrate Collection

CALIBRATEDCONTAINER

BYPASSVALVE ON

FOAM PUMP

BYPASSHOSE

ΙΙΙ -10



Figure 3-9. Relief Valve

FOAMMASTERFOAM PUMPASSEMBLY

DISTRIBUTIONBOX

ELECTRICMOTOR

PRESET RELIEFVALVE

RELIEF VALVEThe pressure relief valve (see figure 3-9) 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 Servicebulletin.

RETSAMMAOFELAHLEDOM

TESEVLAVFEILERERUSSERP

0.5LEDOM )RAB12(ISP003





SYSTEM



SECTION IVOPERATION

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

IV-1


Section IV: Operation




















IV-2























IV-3



Figure 4-1. Control Unit Identification

BARGRAPH(LIGHTS TO APPROXIMATE

CAPACITY WHEN FOAM PUMP ISRUNNING)

ON PUSHBUTTON(TURNS THE HALE FOAMMASTER

SYSTEM ON AND OFF. LIGHTSWHEN THE SYSTEM IS ON)

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

PUSHING BOTH AT THE SAME TIME WILL RESET TOTAL VALUES)

LEDs(LIGHT TO INDICATE FUNCTION

SELECTED)

SELECT DISPLAY(SELECTS CONTROL UNIT

FUNCTION AS INDICATED BYLABEL AND LED AT LEFT)

OPERATING INSTRUCTIONSSYSTEM OPERATION DESCRIPTIONOperation of Hale FoamMaster systems issimple with all control provided by the pushbuttons on the control unit face (see figure 4-1).

Upon initial power up of the apparatus theHale FoamMaster 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 SELECT DISPLAYbutton will change the function indicated bythe LED that is lit under a particular label.TOTAL WATER and TOTAL FOAM values can bereset any time they are displayed. When the% FOAM LED is lit, or in any other functionmode, the foam concentrate injection ratecan be set to the desired value, if differentfrom the default value, prior to or during

foam operations by pressing the � and �buttons.

When the red ON button is pressed, thebutton will illuminate indicating that thesystem is ready. If water flow is present thefoam pump will start and inject foamconcentrate into the discharge stream.The bargraph will light when foam is beinginjected and indicate system capacity.The Hale FoamMaster system constantlymonitors water and foam concentrateflow values maintaining foam injection atthe specified concentrate injection rate.The system responds to variations in waterflow by increasing or decreasing thespeed of the foam pump.

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

DIGITAL DISPLAY(PROVIDES DIRECT READOUT OF

SELECTED FUNCTION VALUES ANDDISPLAYS WARNINGS)

IV-4



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 greySELECT DISPLAY button in the upper righthand corner of the control unit. Each timethe button is pressed a new function modeis selected 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 HPF flowsensor monitoreddischarges. (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

IV-5



concentrate have been used. (Seefigure 4-4)

BARGRAPHThe bargraph (refer to figure 4-1) consists of17 LEDs. The LEDs on the bargraph will lightwhen the foam pump is running andinjecting foam concentrate. The amount ofLEDs 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 theuppermost 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 flashes sothe operator will know the system is 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 SELECT DISPLAY button, selecteither TOTAL WATER or TOTAL FOAM. Bypressing and holding both the � and �

buttons at the same time, the value shownis cleared and displayed as zero.Additionally the totalized values for waterand foam concentrate reset to zeroautomatically when the apparatus power isturned 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 foamMaster 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 FoamMaster system components, theapparatus and cause personnel injury.

FLUSHIf the Hale FoamMaster 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 isflowing then go to standby mode.

Figure 4-4. Total Foam Display

IV-6



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 FoamMaster 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 isdetected the display will show “no A” or“no b”, the pump will stop, and the ON LED

will go out until the foam level is restoredand the ON button is depressed. If the ONbutton is pressed before refilling the foamtank the system will run for 30 secondsbefore shutting down again.

Figure 4-5. Flush Display

Figure 4-6. Low Foam Tank Display

TANK ASELECTED

AFTER 1MINUTE OFOPERATION

TANK BSELECTED

AFTER 1MINUTE OFOPERATION

IV-7



Priming ErrorIn the event there is no feedback signalbeing received when the foam pump isstarted, indicationg 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 FoamMaster system isoperating in an environment of excessiveambient temperature the display will show“hot” to indicate this situation (see figure 4-8). If the circuitry in the Hale FoamMastersystem is being affected by a drop in powersupply voltage the display will show “LobAt”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 conditionsdeteroriate 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

IV-8



NORMAL OPERATION SUMMARY

OPERATION ACTION DISPLAY

INITIAL STARTUP

SELF DIAGNOSTICS

STAND-BY 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 turnFoamMaster power switch toON.

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

IV-9



FOAM CONCENTRATE INJECTION RATEDISPLAY

TOTAL FOAM DISPLAY

TOTAL FLOW DISPLAY

End foam injection Depress ON button.

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

Read total water Press SELECT 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.

STAND-BY DISPLAYSINGLE FLOWSENSOR: FLOW

MULTIPLE FLOWSENSORS: % FOAM

IV-10



The Simulated Flow mode of the HaleFoammaster 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 HaleFoamMaster in Simulated Flow mode anoutlet for the foam concentrate must beprovided to prevent excessive pressurebuildup in discharge piping or hoses.

SIMULATED FLOW OPERATIONUse the following procedure to operate theHale FoamMaster system using simulatedflow:

1. Locate the bypass hose and uncoilto place the end into a suitablecontainer to collect the foamconcentrate.2. Place the Hale Foammaster systemBYPASS valve in the BYPASS position.3. Energize apparatus electrical systemand turn Hale Foammaster power switchto ON.4. When the Hale FoamMaster is in thestandby mode, FLOW LED lit, depressand release the � and � buttons at thesame time. The display will show "S 150"(or other pre-set default value) and theFLOW LED will be lit. (see figure 4-9)5. Depress the ON button. The ONbutton 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 SELECT DISPLAY button until theFLOW LED is lit.

Figure 4-9. Simulated Flow Operation Display

SIMULTANEOUSLYPRESS AND RELEASE

ENTERING SIMULATED FLOW MODE SIMULATED FLOW MODE DISPLAY

IV-11



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

IV-12



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

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

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

2. Flip the Hale ADT toggle switch down orturn the Hale FoamMaster MDT ΙΙ handleuntil the indicator points toward the desiredtank (See figure 4-10). When changingtoggle switch or selector handle position,move smoothly from the TANK A positionthrough the FLUSH position to TANK Bposition in one motion without stopping.With the fire pump discharging water andthe Hale FoamMaster operating, a smallvolume of water will be provided toseparate the two foam types helping toprevent possible reactions.

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 FOAMMASTER 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 FOAMMASTER ADT PLACARD

TANK BINDICATOR

LIGHT(RED)

IV-13



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

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

FLUSHING HALE FOAMMASTERWhen returning the apparatus to readycondition after foam operations using classB foam, the Hale FoamMaster 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 FoamMaster bydepressing the red ON button allowingfoam solution to discharge.

NOTE: When the Hale ADT, MDT ΙΙ or MSTis in the FLUSH position the HaleFoamMaster 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 HaleFoamMaster and discharge to run forseveral seconds.

5. After several seconds place the HaleADT or MDT ΙΙ to the TANK A position andallow Hale FoamMaster 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 FoamMaster torun until Class A foam solution isdischarged through the foam capablehose line. If Class B foam concentrate isused shut down Hale FoamMasterimmediately after switching to FOAMTANK position.

7. Shut down Hale FoamMaster 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

IV-14



PRIMING THE FOAM PUMP WHEN FOAMTANK HAS RUN DRY

In some instances the foam tank may rundry while operating the Hale FoamMastersystem. 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 re-establish 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 HaleFoamMaster on observe the hose fromthe bypass 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 FoamMaster 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 FoamMaster system fromthe driver compartment or a location otherthan the control unit. The switch will onlyactivate and deactivate the HaleFoamMaster 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 FoamMaster 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 FoamMaster systemand the LED will go out.

IV-15



MAINTENANCEMAINTENANCE PROCEDURES1. After each use: Flush Hale FoamMaster

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.

IV-16



TROUBLESHOOTINGUSER DIAGNOSTICSPower indicator lamps are provided on thedistribution box, on the rear of the controlunit (see figure 4-12) and on the feedbacksensor. The lamp on the distribution boxlocated next to the ON/OFF switch isilluminated whenever power is supplied tothe control cable. A similar lamp on therear of the control unit is illuminatedwhenever power reaches the display. TheLED on the feedback sensor will flash whenthe sensor is receiving pulses from theflowsensor. These LEDs help to ease tracingof power supply faults and eliminates someof the guesswork in troubleshooting. Thisfeature is referenced in the troubleshootingguide.

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 FoamMaster.

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

� Power indicator LEDs on the distributionbox and control unit are illuminated.

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

Figure 4-12. Power Indicator LED Location

CONTROL UNIT BACK VIEW DISTRIBUTION BOX TOP VIEW

POWERLED

REMOTEACTIVATION

SWITCHCONNECTION

HPF FLOWSENSORINPUT CONNECTION

CONTROLCORDSET

CONNECTION

POWERLED

ON/OFFTOGGLESWITCH

IV-17



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

PROBLEM ISOLATION

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

Refer to the following to isolate the cause of Hale FoamMaster 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

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

3. If the Hale FoamMaster 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 FoamMaster 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 III of this manualmaking adjustments as required.

IV-18



Chart 4-1. Hale FoamMaster 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

IV-19



Chart 4-2. Power System Troubleshooting

START

CONTROL UNITILLUMINATED?

IS POWER INDICATORLED ON BACK OF

CONTROL UNIT ON?

IS POWER INDICATORLED ON DISTRIBUTION

BOX ON?

IS POWER ISOLATIONSWITCH ON?

PROCEED TO CHART4-1 SYSTEM

TROUBLESHOOTING.

REPLACE CONTROLUNIT

CHECK POWER CABLEINTEGRITY AND REPLACE

CABLE IF NECESSARY

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

YES

NO

NO

NO

NO

NO

NO

YES

YES

YES

IV-20



Chart 4-3. HPF Flowsensor Troubleshooting

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

NO

NO

NO

YES

NO

YES

YES NO

YESNO

NO

YES

NO

YES

START

IV-21



Chart 4-4. Foam Pump Troubleshooting

START

IS FOAMCONCENTRATE

FLOWING?

IS CONTROL UNITDISPLAY

ILLUMINATED?

IS WATERFLOWING?

IS CONTROL UNITON BUTTON

ILLUMINATED?

IS FOAM PUMPMOTOR

OPERATING?

PROCEED WITHNORMAL OPERATION

ESTABLISH WATER FLOWIN ACCORDANCE WITH

APPARATUS OPERATINGPROCEDURE

PROCEED TO POWERSUPPLY


DEPRESSCONTROL UNIT

ON BUTTON

IS CONTROL UNITON BUTTON

ILLUMINATED?

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

IV-22



PARTS IDENTIFICATIONFOAM PUMP ASSEMBLY

REF PART NUMBER DESCRIPTION QTY UNIT501-3110-15-0 (MODEL 3.0) FM 3.0 PUMP ASSY (12 VOLT DC MOTOR)501-3110-24-0 (MODEL 3.0) FM 3.0 PUMP ASSY (24 VOLT DC MOTOR)501-3120-15-0 (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 FOAMMASTER 6-PIN CABLE ASSY 16.41 FT(5 M) LG 1 EA

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

IV-23

RO

TA

RY

GE

AR

PU

MP

EL

EC

TR

ON

IC F

OA

M P

RO

PO

RT

ION

ING

SYST

EM

Sectio

n IV

: Op

eration

16

913

7

21

24

2322

19

22 18

15

1

10

6

12

612

3

1014

26

17

2

25

8

BRASS NUTS ANDWASHERS SUPPLIED WITH

MOTOR ASSEMBLY

28

28

27 27

11

11

20

4

LENGTH OF PIGTAIL ISAPPROXIMATELY 5 FEET.

ATTACH TO 6-PIN CONNECTION ONFOAMMASTER DISPLAY UNIT.

IF REQUIRED USE 6-PIN CABLEITEM #30 AS AN EXTENSION

IV-24



1 038-1790-00-0 CHECK VALVE INJECTOR 1 EA2 101-1630-04-0 FOAM MASTER NAMEPLATE 1 EA3 101-1630-12-0 FOAM MASTER SYSTEM DIAGRAM NAMEPLATE

(SINGLE TANK) 1 EA4 168-0380-01-0 CONTROL UNIT 1 EA5 110-1703-06-0 NUT 1 EA6 012-1440-00-0 TEE HANDLE 1 EA7 012-0450-00-0 HANDLE COVER 2 EA8 018-1003-43-0 SCREW #10-24 X 3/8 IN LG 2 EA9 101-1630-01-0 BYPASS PLACARD 1 EA10 038-1810-00-0 BYPASS VALVE 1 EA11 082-0408-02-0 1/2 INCH NPT CLOSE NIPPLE (BRASS) 1 EA

ADDITIONAL FOAMMASTER SYSTEM COMPONENTSREF PART NUMBER DESCRIPTION QTY UNIT

1

4 32

5

6

8

9

10

11

7

7

IV-25



FOAMMASTER FLOWSENSOR

538-1600-15-0 HPF15 NPT FLOWSENSOR ASSY (1-1/2 INCH NPT)538-1600-16-0 HPF15 ISO FLOWSENSOR ASSY (1-1/2 INCH ISO)538-1600-20-0 HPF20 NPT FLOWSENSOR ASSY (2 INCH NPT)538-1600-21-0 HPF20 ISO FLOWSENSOR ASSY (2 INCH ISO)538-1600-25-0 HPF25 NPT FLOWSENSOR ASSY (2-1/2 INCH NPT)538-1600-26-0 HPF25 ISO FLOWSENSOR ASSY (2-1/2 INCH ISO)538-1600-30-0 HPF30 NPT FLOWSENSOR ASSY (3 INCH NPT)538-1600-31-0 HPF30 ISO FLOWSENSOR ASSY (3 INCH ISO)538-1600-40-0 HPF40 NPT FLOWSENSOR ASSY (4 INCH NPT)538-1600-41-0 HPF40 ISO FLOWSENSOR ASSY (4 INCH ISO)

1 007-2021-00-0 HPF15 NPT FLOWSENSOR TEE 1 EA007-2021-10-0 HPF15 ISO FLOWSENSOR TEE 1 EA007-2021-01-0 HPF20 NPT FLOWSENSOR TEE 1 EA007-2021-11-0 HPF20 ISO FLOWSENSOR TEE 1 EA007-2021-02-0 HPF25 NPT FLOWSENSOR TEE 1 EA007-2021-12-0 HPF25 ISO FLOWSENSOR TEE 1 EA007-2021-03-0 HPF30 NPT FLOWSENSOR TEE 1 EA007-2021-13-0 HPF30 ISO FLOWSENSOR TEE 1 EA007-2021-04-0 HPF40 NPT FLOWSENSOR TEE 1 EA007-2021-14-0 HPF40 ISO FLOWSENSOR TEE 1 EA

2 008-0710-00-0 HPF 2-1/2 NS THD CAP 1 EA3 013-1680-00-0 HPF GROUND TERMINAL 1 EA4 013-2010-04-0 FOAMMASTER 4-PIN CABLE ASSY 13.12 FT

(4 M) LG (STD) 1 EA013-2010-01-0 FOAMMASTER 4-PIN CABLE ASSY 3.28 FT (1 M) LG (OPT) 1 EA013-2010-02-0 FOAMMASTER 4-PIN CABLE ASSY 6.56 FT (2 M) LG (OPT) 1 EA013-2010-05-0 FOAMMASTER 4-PIN CABLE ASSY 16.41 FT

(5 M) LG (OPT) 1 EA013-2010-06-0 FOAMMASTER 4-PIN CABLE ASSY 19.69 FT

(6 M) LG (OPT) 1 EA5 018-0602-44-0 SCREW-#6-32 X 1/4 1 EA6 040-1270-07-0 O-RING 2 EA7 064-6360-00-0 HPF LOCATING PIN 1 EA8 101-1610-00-0 HPF CAUTION DECAL 1 EA9 200-2491-00-0 HPF SENSOR ASSY 1 EA

REF PART NUMBER DESCRIPTION QTY UNIT

IV-26



1

3

7

6

82

9

5

4

IV-27



HALE FOAMMASTER 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 MASTER 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

IV-28



1

10

9

18

15

2

20

17

4

5

8

16

19

11

12

13

21

3

14 6

7

24

23

IV-29



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.

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