Systems 2001, 2002 and 2002HPpneumaxcafs.com/manuals/Support Docs/FoamPro...Systems 2001 and 2002 A QUICK LOOK AT HOW THE SYSTEM WORKS The FoamPro 2001 and 2002 systems are electric

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Installation and Operation Manual

S y s t e m sS y s t e m s2001 and 2002

INSTALLATION ANDOPERATION MANUAL

Form 82502/02

All quality FoamPro products are ruggedly designed, accurately machined, carefully assembled, thoroughlyinspected and tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it isimportant to follow the instructions on care and operation. Proper use and good preventive maintenance willlengthen the life of your unit. ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN CORRESPONDENCE.

UnitSerialNumber

FoamPro by Hypro Corporation • 375 Fifth Avenue NW • New Brighton, MN • (651) 766-6300 • FAX (651) 766-6614

S y s t e m s2001, 2002

and2002HP

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TABLE OF CONTENTSSECTION PAGE

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

2 A QUICK LOOK AT HOW THE SYSTEM WORKS ............................................................... 4

3 SYSTEM COMPONENT DESCRIPTION .............................................................................. 5

4 INSTALLER SUPPLIED PARTS ............................................................................................ 7

5 INSTALLATION PLANNING .................................................................................................. 9

6 PLUMBING COMPONENT INSTALLATION AND HOOK-UP ............................................. 10

7 ELECTRICAL EQUIPMENT INSTALLATION ...................................................................... 15

8 MAKING SURE EVERYTHING IS WORKING RIGHT ........................................................ 21

9 CALIBRATION AND SETUP............................................................................................... 23

10 OPERATING INSTRUCTIONS ............................................................................................ 27

11 MAINTENANCE ................................................................................................................... 31

12 TROUBLESHOOTING ......................................................................................................... 32

13 PARTS IDENTIFICATION.................................................................................................... 36

14 INSTALLATION DRAWINGS ............................................................................................... 38

15 WARRANTY ........................................................................................................ BACK PAGE

NOTE TO SYSTEM INSTALLERIMPORTANT: Please provide a copy of the FoamPro manual to the end user of the equipment. Foradditional manuals, contact Hypro Corporation by FAX (651) 766-6614 or call (651) 766-6300. Askfor Form No. 825.

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1. Do not pump at pressures higher than themaximum recommended pressure (400 psi[28 BAR]).

2. Do not permanently remove or alter anyguarding devices or attempt to operate thesystem when these guards are temporarilyremoved.

3. Always disconnect the power sourcebefore attempting to service any part of thepump. Note this system contains acapacitor which will hold a charge for a timeafter power is disconnected. Take care todissipate this charge, by connecting a12 or 24 volt test lamp from the pump baseto the positive main power terminal.

4. Release all pressure within the systembefore servicing any of its components.

5. Drain all concentrate and water from thedischarge system before servicing any of itscomponent parts.

6. Check all hoses for weak or worn conditionsafter each use. Ensure that all connectionsand fittings are tight and secure.

7. From the foam pump outlet to the injectorfitting, use only pipe, hose, and fittings thatare rated at or above the maximum pressure(400 psi [28 BAR] minimum for 2001 &2002and 600 psi [41 BAR] for 2002HP) ratingthat the water pump system operates.

8. Any electrical system has the potential tocause sparks during service. Be sure toeliminate explosive or hazardousenvironments during service/repair.

9. CAUTION: Do not attempt to operate thesystem at or above a temperature of 160oF[71oC].

SAFETY10. CAUTION: Be sure that the electrical

source of power for the 2001 and 2002 unitsare 12 volt, the 2001/24 and 2002/24 are24 volt, all with negative-ground DC. Thesystems require a minimum current rating ofat least:22 amps for System 24 Volt 2001;

41 amps for System 12 Volt 2001;

56 amps for System 12 Volt 2002& 2002HP;

30 amps for System 24 Volt 2002& 2002HP.

11. CAUTION: Periodically inspect the pumpand the system components. Performroutine preventive maintenance as required.Failure to perform routine maintenance maydamage the pump. See the maintenancesection of this manual for recommendedmaintenance procedures and intervalsbetween maintenance work.

12. CAUTION: Read and understand the“Operating Instructions” section beforeattempting to operate the unit.

13. CAUTION: Always disconnect the groundstraps and control cables from the DigitalDisplay Control Module or other FoamProequipment before electric arc welding at anypoint on the apparatus. Failure to do so willresult in a power surge through the unit thatcould cause irreparable damage to thedisplay or other system components.

14. CAUTION: The cables shipped with eachFoamPro unit are tested at the factory.Improper handling and forcing connectionscan damage these cables which could resultin other system damage.

Please read all of the following safety precautions andfollow carefully. They are important to the prevention ofpersonal injury or damage to the equipment.1

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A QUICK LOOK AT HOW THE SYSTEM WORKSThe FoamPro 2001 and 2002 systems areelectric motor-driven, flow-based proportioningsystems that measure water flow and then injectthe proportional amount of foam concentrate tomaintain the preset percentage. The basicFoamPro 2001 and 2002 systems are shown inFigure 1. The systems will accurately deliverfrom 0.1% to 3.0% foam concentrate to thefoam injector fitting. The flowmeter measuresthe water flow and sends a signal to the DigitalDisplay Control Module. Another sensingdevice monitors the foam pump output.Constant comparison of these two informationsignals by the computer ensures maintenanceof the desired proportion of foam concentrate atall times based on the water flow rate,independent of any variations in fire pumpintake or discharge pressures. As water flow

Figure 1. FoamPro System Layout

increases or decreases, the foam concentraterate of injection is increased or decreasedautomatically to correspond to the water flow.

Foam concentrate is injected directly into thewater stream on the discharge side of the waterpump. It is then fed as foam solution by themain fire pump into a standard fog nozzle, anair aspirated nozzle, or CAFS equipment.

Since foam is injected on the discharge side ofthe fire pump and check valves are to be usedat installation, contamination of the boostertank, fire pump and relief valve with foamconcentrate is eliminated.

Order optional system components listed inSection 3 to accommodate system design andrequirements.

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SYSTEM COMPONENT DESCRIPTION

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STANDARD FOAMPRO 2001 and 2002 EQUIPMENTThe following components are packaged with theFoamPro 2001 and 2002

1. DIGITAL DISPLAY CONTROL MODULE2. MOLDED CABLES3. FOAM PUMP ASSEMBLY4. INSTRUCTION PLATE5. TANK LOW LEVEL SENSOR (One

required. Not packaged with the unit.Order separately.)

6. CALIBRATE/INJECT VALVE withBUSHING (Attached to the pump outletconnection.)

7. INLET LINE STRAINER WITH NIPPLE

8. FOAMPRO PADDLEWHEEL FLOWMETER(The flowmeter is a required component andmust be ordered separately. When ordering the2001 or 2002, specify the flowmeter size basedon end use requirements. The flowmeters areavailable with 1-1/2 NPT x 1" Bore, 1-1/2, 2,2-1/2, 3 and 4 inch NPT threads. (Part numbersand flow ranges for the various flowmeters canbe found on Page 41.)

9. 1/2 INCH NPT FOAM INJECTION CHECKVALVE. This NFPA 1906 required check valveprevents water back flowing into foam systems.

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Vertical Mount(P/N 2510-0028)

Side Mount(P/N 2510-0032)

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To Operator:

1. Push red foam button. Light below switch will indicate unit is operating and will flashwhen foam is being injected.

2. Change foam percentage usingkeys.

3. Gray select button will display water flow, total water flowed, foam concentration and total foamflowed. Push keys together to reset total values.

4. To shut down, depress the red foambutton.

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Read and UnderstandOperating Manual

800-533-9511

HYPRO

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SYSTEM ACCESSORIES AVAILABLE

PolypropyleneFoam Tank(s)8 gallon,P/N 1530-000512 gallon,P/N 1530-001220 gallon,P/N 1530-0013

Provides automatic 8 second flush offoam pump and injection lines toprevent mixing of foam concentrates.12 VDC P/N 3435-010424 VDC P/N 3435-0105

Electronic Dual Tank System withAutomatic Flush

2-Tank Manual Valve(12 or 24 volt DC)P/N 3435-0079

Remote Start/Stop (12-volt DC only)P/N 3435-0075

System PlacardP/N 6032-0015 Single Tank orP/N 6032-0016 Dual Tank

FoamPro MultiFlow InterfaceThe basic system requires atleast one flowmeter to sensewater flow in the dischargepiping. The FoamPro Multiflointerface allows a total of fourflowmeters to be used. Thedisplay will show the dischargeflow on the selected flowmeter.(P/N 2527-0047)

System Specification PlacardsSystem 2001 P/N 6032-0020System 2002 P/N 6032-0021System 2002HP P/N 6032-0035

Main Waterway Check Valve1-1/2" NPT thread P/N 3320-00302" NPT thread P/N 3320-00312-1/2" NPT thread P/N 3320-00323" NPT thread P/N 3320-00334" NPT thread P/N 3320-0034

¤

A WICOR COMPANY

¤

To calibrationcontainer

FoamTank"A"

FoamTank"B"

Foam Pump

Shut OffValve

CheckValve(s)

From mainwater pump

CheckValve

Strainer Strainer

➡

➡

➡

➡

➡

➡

➡

➡

➡

Manual Flush Valve

TANKA B

TANK

FLUSH

FOAM SELECTOR

®

¤¤

FoamPro 2001 SpecificationsConcentrate class type: A and/or BMaximum concentrate viscosity: 2000 cpsConcentrate proportioning rate: 0.1%-9.9%Concentrate injection rate: 0.1-2.6 gpmMaximum injection pressure: 400 psiMaximum solution capability: 0.5% 520 gpm(performance at 150 psi) 1.0% 260 gpm

3.0% 85 gpm6.0% 43 gpm

Results may vary due to system configuration. See operator’s manual for further details.

800-533-9511

FOAM B

¤

FOAM A

FOAM A

LIGHT w/RED LENS

4-POLERECEPTACLE

RED BUTTON

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FOAM CONCENTRATE SUCTION LINEFittings and hoses from the foam tank to theinlet of the foam pump must be used. Use3/4 inch [19 mm] minimum inside diameter orlarger hose dependent on the viscosity of thefoam concentrate. Use components that arerated for 23 in [584.2 mm] Hg vacuum and50 psi [3 BAR[ pressure or greater. Thecomponents must be compatible with all foamconcentrates to be used. Fittings used must bemade of brass, 300 series stainless steel orother corrosion resistant material. Beforeselection of hose fittings, check for compatibilitywith foam concentrates to be used. The use ofclear suction hose is required by NFPA to allowviewing foam priming operations. The foampump must be positioned to allow gravity feedfrom the foam tank(s).

NOTE: When using a Dual Tank System,intake plumbing will be different. Refer toDual Tank System Manual for foam pumpinlet plumbing installation.

FOAM CONCENTRATE DISCHARGE LINEFittings and hoses from the discharge of thefoam pump to the injector fitting must besupplied by the installer. Hoses and fittings of1/2 inch [13 mm] minimum INSIDE diameterrated at 400 psi [28 BAR] minimum workingpressure for the 2001 & 2002, 600 psi [41 BAR]for the 2002HP or maximum discharge pressureof the fire pump, whichever is greater, must besupplied by the installer. Fittings and hosesmust be compatible with all foam concentratesto be used. Use fittings of brass, 300 seriesstainless steel or other corrosion resistant

material compatible with all foam concentratesto be used.CHECK VALVESNFPA 1901 & 1906 requires installation of acheck valve in the foam concentrate injectionline. To prevent foam concentrate flow from thetank due to static head pressure, the foamconcentrate check valve shall have a4 to 6 psi [0.1 to 0.3 BAR] cracking pressureand shall be capable of withstanding thepressures that will be generated in the foaminjection line.

A check valve is also required in all water pipinglocations where foam concentrate could drainback into pumps or other components of the fireapparatus. As a minimum, one check valvemust be installed where the foam solution waterpiping connects to the fire pump discharge.(FoamPro main waterway check valve isrecommended.)

Multiple drains that allow individual drain lines tocommunicate may allow foam to short circuitpast the check valves; avoid this possibility.FoamPro recommends separate drain valve(s)for the discharge piping.

FOAM CONCENTRATE TANK(S)Foam concentrate tank(s) must be supplied tosuit the capacity required for the apparatusapplication. The tank(s) should meet NFPAminimum standards for the design capacity,including filler size, vapor pressure venting anddrain facility. For example, to meet NFPA 1901requirements using 1% AFFF foam concentrate,a 40 gallon foam tank is required.

The FoamPro 2001 and 2002 systems are provided with the major components and accessoriesrequired for installation. Due to differences in chassis and apparatus configurations, the installermust provide pipe, hoses, tubing, wire and fittings to satisfy installation requirements. Thefollowing paragraphs list the specifications for selection of these components. Before beginningsystem installation, read this section thoroughly to make sure the proper components are selected.For detailed system installation instructions, refer to Sections 5, 6 and 7.

INSTALLER SUPPLIED PARTS4

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ELECTRICAL REQUIREMENTSElectrical wiring must be supplied from the mainapparatus electrical system to the foam pumpbase unit. Use a minimum of 8 AWG wirebecause minimum electrical service is asfollows:

2001 12 VDC requires 41 amps;2002 or 2002HP 12 VDC requires 56 amps;2001 24 VDC requires 22 amps;2002 or 2002HP 24 VDC requires 30 amps.

The electrical power must be supplieddirectly from the battery or the batterymaster disconnect switch.

Braided flat ground straps are required forground connections. The flat straps limit theRFI/EMI interference encountered with radios,computers or other sensitive electronicequipment.

CAUTION: Always disconnect the groundstraps and control cables from the DigitalDisplay Control Module or other FoamProequipment before electric arc welding at anypoint on the apparatus. Failure to do so willresult in a power surge through the unit thatcould cause irreparable damage to the display.

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INSTALLATION PLANNINGBecause of the potential differences inapparatus plumbing and foam systemconfiguration, it is not practical to depict exactlyhow each FoamPro unit can best be installedonto a particular apparatus. Figure 2 shows therelative location of the FoamPro systemcomponents. Most of the information containedin the following sections, however, will apply toany situation.

It is recommended that you read thefollowing sections thoroughly beforebeginning installation of the FoamProsystem. It is also recommended that youspend time planning and designing whereand how you intend to install this unit in theapparatus before beginning the actualinstallation.

Determine the locations of the components tobe installed such as; foam tank(s), foam pumpand flowmeters. Try to place components inlocations that require the least amount of hosesand fittings.

Locate the foam pump unit in an area that isprotected from road debris and excessive heatbuildup. Since the master power switch and

Figure 2. System Component Location

CAL/INJECT valve are located on this unit, thefoam pump unit should be installed in anaccessible compartment located in the vicinity ofthe operators panel.

The foam pump unit should be located belowthe discharge of the foam tank(s) to provide forgravity feed to the foam pump. Locate the foamtank(s) where the refilling can be done with5 gallon (19 liter) containers and other methodssuitable to the end user. Most water tankmanufacturers will build the foam tank(s) intothe booster tank. When specifying integral foamtank(s), make provisions for installing the lowtank level sensor as well as foam suctionconnections and tank drainage.

Determine a location for the Digital DisplayControl Module on the operator panel of theapparatus. Consider the routing path for thecontrol cables from the Digital Display ControlModule to the foam pump unit and flowmeter(s).If necessary, order longer or shorter cableassemblies to suit the location demands.

CAUTION: Never attempt to cut or lengthen themolded cables.

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PLUMBING COMPONENT INSTALLATIONThe following diagram (Figure 3) provides recommended guidelines for the location of the systemcomponents that handle water, foam concentrate and foam solution. Note that additional optionssuch as dual tank systems, multiple flowmeters, etc., are covered by individual manuals includedwith those systems; consider potential interferences.

Figure 3. FoamPro 2001/2002 System Piping

A. FOAM PUMP/MOTOR BASE ASSEMBLYThe foam pump/motor base assembly must bemounted in a horizontal position (See Figure 5).The base of the foam pump must be anchoredto a surface or structure that is rigid and ofadequate strength to withstand the vibration andstresses of apparatus operation. Figure 4provides the mounting dimensions for theFoamPro 2001 and 2002 foam pump/motorbase assembly. It is required to use flexiblehose when making the hose connections to theFoamPro 2001 and 2002. DO NOT hard pipethe system.

Position the foam pump so the circuit breaker/on-off switch is easily accessible. Also,consider access requirements for checking and

changing the oil in the crankcase of the foampump. Be sure the foam concentrate hoses canbe properly routed to the inlets and outlets onthe foam pump. Foam concentrate shouldgravity feed to the foam pump inlet from thefoam tank(s). The foam pump/motor baseassembly must be mounted in an area to avoidexcessive exhaust system heat buildup.

Protect the hoses and wiring from chafing andabrasion during operation of the foam system.

Protect the foam pump base unit from excessiveroad spray and debris. Although the system issealed and designed to be resistant to the harshenvironment of fire fighting apparatus, a

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protected location with easy operator access isthe ideal installation location.

After the foam pump/motor base assembly ismounted, remove the shipping plug in the oil fillhole on the foam pump gear case and replace it

with the vented oil dipstick (see Figure 6).Check the oil level by removing the venteddipstick; make sure the oil level is to the fullmark on the dipstick. Proper oil level is alsoindicated when the oil is visible in 1/2 to 3/4 ofthe oil level sightglass. Add SAE 30 weightnon-detergent oil if required. Replace thedipstick when the oil level is correct.

B. DISCHARGE RELIEF VALVEThe discharge relief valve is installed on theoutlet port of the foam concentrate pump. It isprovided to protect the foam pump fromexcessive pressures. The relief valve is factoryset at 400 psi [28 BAR] (600 psi [41 BAR] for2002HP model).

Figure 6. FoamPro 2002 FoamPump Oil Level Check

Figure 4. FoamPro 2001/2002 Mounting Dimensions

C. CAL/INJECT VALVEThe CAL/INJECT valve is mounted on thedischarge side of the foam proportioner. Thisvalve shall be accessible by the pump operatorduring normal operations. The valve is a 3-waydirectional valve that selects where the output ofthe foam pump will go.

Check to make sure the valve is installedproperly. Look at the ports as you move thehandle, the flow should go from the center portto each of the other ports.

The hose and fittings from the INJECT port tothe foam injector fitting should have 1/2 inch[13 mm] inside diameter and be rated at400 psi [28 BAR] for 2001/2002 models or 600psi [41 BAR] for 2002HP models minimumworking pressure or maximum dischargepressure of the fire pump.

HorizontalMounting Vertical

Mounting

DO DON’T

Figure 5. Foam Pump Mounting Position

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The hose from the CAL/FLUSH port may have alower pressure rating since it is plumbed to theatmosphere and will not receive high pressures.This hose is used for calibrating the foam pump,pumping the concentrate into a container toempty the tank or to assist in priming of thefoam pump. The hose from the CAL/FLUSHport must be long enough to reach a containeroutside the truck. This hose must be coiled forstorage when not in use.

D. LINE STRAINERThe line strainer that is provided with theFoamPro unit has 3/4 inch NPT female threadedports and is to be installed on the inlet port sideof the foam pump. The hose from the foam tankshould have adequate wall stiffness to withstandthe vacuum of the foam pump while it isoperating (23 in. [584 mm] Hg and 50 psi[3 BAR]).

NOTE: If a pressurized water flush from one ofthe discharges is incorporated, the plumbing andline strainer exposed to this pressure must berated at or above the operating pressure of allother discharge plumbing components. (400 psi[28 BAR] minimum) (600 psi [41 BAR] for2002HP models).

E. FLOWMETER(S)The FoamPro System 2001 and 2002 aredesigned to accept flow reading signals from theFoamPro paddlewheel style flowmeter.

Proper flowmeter sizing is critical to systemaccuracy. Select a flowmeter size based onactual flows required, not standard pipe sizes.Refer to the installation drawing at the end ofthis manual (Page 39) for proper flowmeter sizing.

The flowmeters require that the amount ofturbulence in the pipe being monitored is as lowas possible. Excessive turbulence producesunstable and inaccurate flow readings. Thefollowing installation guidelines will help attainthe best readings and maintain accuracy of theFoamPro system.

Figure 7. Flowmeter Placement

a. A minimum 5 times the pipe diameter ofstraight run pipe without any fittings isnecessary upstream of the flowmeter.10 times is better — the longer the straightrun, the lower the turbulence. Here aresome examples of required straight run:

Pipe RecommendedSize Straight Run Pipe

1-1/2 in. [38 mm].... 7-1/2 to 15 in. [191 to 381 mm]2 in. [50 mm] ........ 10 to 20 in. [254 to 508 mm]2-1/2 in. [64 mm].... 12-1/2 to 25 in. [317 to 635 mm]3 in. [76 mm] ........ 15 to 30 in. [381 to 762 mm]4 in. [100 mm] ...... 20 to 40 in. [511 to 1016 mm]

b. The downstream plumbing of the flowmeteris not as critical; but again, straight runswithout fittings help maintain accurate flowreadings.

c. Do not mount a flowmeter directly afteran elbow or valve. Valves create severeturbulence when they are “gated-down”.

d. Try to mount the flowmeters in a positionthat is accessible for routine inspection andmaintenance.

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Injector AboveHorizontal Plane

DO

DON'T

Injector BelowHorizontal Plane

INJECTOR ABOVEHORIZONTAL PLANE

DO

INJECTOR BELOWHORIZONTAL PLANE

FOAMPRO PADDLEWHEELFLOWMETERSThe FoamPro paddlewheel style flowmeterfittings are specially designed tees that makeinspection and maintenance of the flow sensoreasy. The threads of the tees are NPT. Inhorizontal runs the tees should be mounted asclose to upright as possible within the rangeshown in Figure 8.

With the use of a MultiFlo interface, two to fourflowmeters may be monitored simultaneously.A single injection point that will supply foamagent to all foam discharge outlets is required.

F. INJECTOR FITTINGThe brass injector fitting ensures foamconcentrate is injected into the center of thewater flow for better mixing. It is designed to fitinto a 1 inch NPT threaded connection on a pipetee that is installed in the discharge piping of thefire pump (See Figure 9). The inlet of the fittingis 1/2 inch NPT female thread and the outerthreads are 1 inch NPT. The injector may alsobe inserted into a weldfitting with 1 inch NPTfemale threads. ItMUST be mounted ina place that iscommon to alldischarges whichrequire foamcapability. This fittingis not used if using a

FoamPro Main Waterway Check Valve. Aseparate injection point is not possible for eachdischarge. If multiple flowmeters are used, theinjector must be installed before the flow metersat the inlet to their common manifold (SeeFigure 10).

Most foam concentrates by nature mix withwater very quickly, so each discharge from amanifold will receive equal concentrations if themanifold is properly designed and installed.

G. CHECK VALVESA 1/2 inch NPT check valve meets NFPArequirements for a non-return device in thefoam injection system. To prevent foamconcentrate flow from the foam concentrate tankdue to static head pressure, the foamconcentrate check valve shall have a 4 to 6 psi[0.1 to 0.3 BAR] cracking pressure and shall becapable of withstanding the pressures that willbe generated in the foam injection line. It isalways a good idea to inject foam at a horizontalor higher angle to allow water to drain away

Figure 9. InjectorFitting Installation

Figure 10. Injector Fitting Placement forMultiple Discharges

Figure 11. Foam Injector Position

DON’T

Figure 8. Flowmeter Position Range

TEE SHOWN WITHOUTSENSOR INSTALLED

85°Max.

85°Max.

InjectorFitting

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from the check valve (see Figure 11).This will avoid sediment deposits or theformation of an ice plug.

The check valve in the water way is required tokeep foam solution out of the main pump andallow pump priming without drawing foam intothe piping. See Figure 12.

H. DRAIN LINESOn apparatus with multiple drain lines, thedrains from the foam solution discharge lineshould not be piped into a multi drain systembefore the check valves. The standard multidrain system from most manufacturers will allowcross talk between the drain lines and theapparatus water tank, resulting in contaminationof the water tank with foam. A separate drainsystem should be provided for the foam solutionpiping to prevent contamination of the watertank and fire pump.

Figure 12. RecommendedMidship Pump Installation

I. FLUSHING SYSTEMDepending on the corrosiveness of the foamconcentrates to be used, a flushing system maybe required in the foam concentrate injectionsystem. Generally, all Class B foamconcentrates must be flushed from the systemafter use. Most Class A foam concentrates areless corrosive and therefore may not requireflushing. Fig. 12-4 is a recommended diagramfor a flush circuit. When a dual tank system isinstalled on the apparatus, provision for flushingthe foam concentrate injection system is builtinto the dual tank selector system.

Minimum Length ofNipple for 2-1/2''[158.75 mm] Pipe is12-1/2"[317.50 mm].Refer to the Table onPage 12 for therecommended Nipplelengths for differentpipe sizes.

Main WaterwayCheck Valve

Drain Line

Check ValveInjection PortDrain Port

Flowmeter

From FoamTank

Foam StrainerMounted On Foam

Pump Inlet

3/4 IN. IDHose

CheckValve

CheckValveFrom

FirePump

Flush WaterShut-Off Valve

Figure 12-4Foam Concentrate Flushing System Diagram

Flushing Foam PumpsWhen returning the apparatus to ready condition afterfoam operations, the FoamPro foam pumps should beflushed. The following procedures can be used to flushthe foam pumps. Refer to Figure 12-4 and do thefollowing:1. Energize apparatus and establish water flow

through foam solution discharge.2. Close foam concentrate tank shut-off valve and

open flush water supply valve.3. Energize FoamPro 2000 and allow electric motor

driven foam pump to run until discharge is clear.4. Shut off FoamPro 2000 system by depressing the

FOAM button on the Digital Display Control Module.Close flushing water supply valve.

5. Close foam solution discharge and shut downapparatus.

6. Open foam concentrate tank shut-off valve.7. Perform required maintenance checks on the

FoamPro 2000.

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ELECTRICAL CONNECTIONSFollow the system electrical diagram (Figures 13and 14) for proper hookup of each of theelectrical components. Complete molded cablesets are provided with each FoamPro system tomake all the necessary connections. Thecables are color coded and “indexed” so theyonly go in the correct receptacle and they canonly go in one way. DO NOT FORCEMISMATCHED CONNECTIONS. The systemcan only perform when the electrical connectionsare sound, so make sure each one is right.

SOME THINGS TO KEEP IN MIND• DO NOT hook up the main power cables until all

connections are made to each of the electricalcomponents. The last connection should be thepower cable to the foam pump/motor baseassembly.

ELECTRICAL EQUIPMENT INSTALLATION

Figure 13. FoamPro 2002 Electrical Wiring Diagram

• WARNING: This system contains a capacitoron the input power. Connect the leads withthe battery off or disconnected. Current willflow even with the master circuit breaker off.

• DO NOT cut molded cables.

• Provide at least the following amounts ofelectrical power from the battery to the mainpower terminal:

2001 requires 41 amps;2002 requires 56 amps;2001/24 requires 22 amps;2002/24 requires 30 amps.

Use 8 AWG (minimum) wire directly to thebattery or battery master disconnect switch.

• The S105-2001, S105-2002 and S105-2002HP systems are designed for 12-volt,negative-ground systems only. The S205-2001, S205-2002 and S205-2002HP systemsare designed for 24-volt, negative-groundsystems only.

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• Do not mount radio transmitter or transmittercables in direct or close contact with theFoamPro unit.

• Use care when installing molded cables.Count pins or check color codes beforeconnecting. Bent pins caused by improperhookup can prevent proper operation evenwhen cables are reattached properly.

• Before connecting the molded cables,inspect the yellow seal washer in the femaleconnector. If the seal washer is missing ordamaged, water can enter the connector andcause corrosion of the pins and terminalsthat will cause system failure.

• CAUTION: The cables shipped with eachFoamPro unit are tested at the factory withthat unit. Improper handling and forcingconnections can damage these cables,which could result in other system damage.

• CAUTION: Always disconnect the groundstraps and control cables from the DigitalDisplay Control Module or other FoamProequipment before electric arc welding at anypoint on the apparatus. Failure to do so willresult in a power surge through the unit thatcould cause irreparable damage to thedisplay or other system components.

A. DIGITAL DISPLAY/CONTROL MODULEThe Digital Display Control Module is designedto be mounted in the operator panel of theapparatus. The cutout that will be needed in theoperator panel is a 3-7/8 inch [98 mm] diameterhole (the same as a 3-1/2 inch [89 mm] pressuregauge). The display is secured with four #10socket head screws in the four holes in the face(See Page 40 for a mounting template). Thedisplay requires 5 inches [127 mm] minimumfrom the back of the operator panel to clear

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Figure 16. Motor Driver Box Connections

Figure 15. Digital Display ControlModule Cable Connections andGrounding

SPEED SENSOR

TANK SENSOR

CONTROLLER

CAPACITOR

DIODE

CIRCUIT BREAKER

ON

OFF

+

+

* Connections to be made during installation.

*

*

wires and connectors. Make sure there isenough clearance behind the operator’s panelfor the cables. Once the Digital Display ControlModule is mounted, connect the control cable(red coded cable end) from the motor driver boxterminal to the 5 pin connector on the back of

the Digital Display Control Module (seeFigure 15). A color coded decal on the motordriver box identifies each cable connection (seeFigure 16).

NOTE: Make sure the panel where the DigitalDisplay Control Module is mounted has anadequate ground. For stainless steel and vinylcoated panels, a flat ground strap must beattached from one of the four screws holdingthe Digital Display Control Module in place, tothe frame of the fire truck to ensure adequategrounding (see Figure 15).

B. FLOWMETER(s) CONNECTIONS FOAMPRO FLOWMETERIf a single FoamPro paddlewheel type flowmeteris to be used, a molded cable that connectsfrom the flowmeter to the 3 pin connector on theDigital Display Control Module is supplied.

MULTIFLO FLOWMETER INTERFACEMODULESSee the instructions supplied with the MultiFlointerface for installations requiring multipleFoampro flowmeters. Figure 17 shows theinterconnection of the flowmeters with theDigital Display Control Module.

C. FOAM TANK CONNECTIONSThe foam tank low level sensor must bemounted into the bottom of the foam tank tomonitor low foam concentrate level. The switchhas 1/8 inch NPT threads. Mount the sensor inthe bottom of the foam tank in an uprightposition. Use suitable sealant to preventconcentrate leakage. There must be spaceunder the tank for the cable to be routed to thepump base assembly (See Figure 18). Be surenot to remove the float from the shaft on thesensor assembly. If installed in the reverseposition, "LO CON" and "NO CON" will appearon the Digital Display Control Module, and thesystem will automatically shut down after twominutes, even if there is foam in the tank.

When the bottom of the foam tank is notaccessible, the low level sensor float switch can

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Figure 18. Foam Tank Low Level SensorMounting Options

be hung from a long nipple attached to the topof the tank. The nipple should be rigid enoughto withstand the force of sloshing foam when thevehicle is in motion. Make sure the low levelsensor does not contact the side of the foamtank when the vehicle is in motion (See Figure18). Since wire connections must be madeinside the nipple, a 3/8 inch NPT nipple with 3/8

by 1/8 inch NPT reducer at the lower end is theminimum size recommended.

CAUTION: The foam tank low level sensor mustbe utilized to protect the foam pump from dryrunning. Failure to do so will void the warranty.

Connect the sensor wires to the low tank sensorcable (blue coded cable ends). The low tankswitch sensor cable may be shortened orlengthened (use 18-22 AWG). It has pigtails atone end and is not polarity sensitive. Connect

the other cable end to the motor driver box onthe foam pump/motor base assembly (seeFigure 16).

Check low level sensor operation afterinstallation using a powered test light. With nofoam in the tank, the light should be on. If thisis not the case, remove the clip from the end ofthe sensor. Remove the float and reinstall 180o

out of position. Reinstall clip.

A side mount low tank sensor is available to beused if both the top and bottom of the tank isnot accessible (See Figure 18). The side mountlow tank sensor has 1/2 inch NPT threads andthe center of the switch must be locatedapproximately 2 inches [51 mm] from the bottomof the foam tank with the float positioned on topof the switch to move up and down.

NOTE: When the side mount low tank sensorsenses a low concentrate condition, thesystem will operate for two minutes unlessthe foam concentrate level is restored. If thefoam concentrate level is not restored, thesystem will shut down after two minutes.When locating the side mount low tank levelswitch on the foam tank, sufficient foamvolume must be present for two minutes ofoperation. This determination will be madeusing the most frequent foam concentrateinjection rate and water flow.

The side mount low tank sensor must be sealedwith a suitable sealant to prevent concentrateleakage. After installation, check operation ofthe side mount low tank sensor with a poweredtest light. With no foam in the tank, the lightshould be on. If light does not come on, rotatethe side mount low tank sensor until the testlight is on. The float should be allowed to swingup and down freely.

D. DC MOTORProvide adequate electrical power (see thelisting on Page 15) from the battery. Use8 AWG minimum wire directly to the battery orbattery switch. Long wire runs may require6 AWG wire for proper operation.

Figure 17. Multiflo and FlowmeterConnections

Top Mount

Low Tank Sensor

BOTTOM MOUNT

Side MountTank Sensor(OPTIONAL)

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F. EMI/RFI SUPPRESSIONAn EMI/RFI (Radio Frequency Interference)suppression kit is included with each FoamProsystem. The clamp-on beads included in the kit,when properly installed, along with propergrounding of components will reduce thepotential for radio frequency interference.Additionally, make sure radio cables andhardware are not located in the immediate areawhere the FoamPro 2001 or 2002 equipment ismounted.

Install clamp-on beads at the locations indicatedin Figure 19. Slide the beads as close aspossible to the connectors on the cable. Use asmall amount GE SILICONE II, electrical tape orheat shrink tubing to keep the beads frommoving after installation.

Recommended wire sizes

Wire Size Wire Length (approximate)

8 awg 10 feet or less

6 awg 10-20 feet or less

4 awg 20 feet or more

E. POWER SUPPLYElectrical devices can be easily damaged by aweak or erratic power supply. The FoamPro2001 and 2002 systems are no different — thebetter the power supply, the better the FoamPro2001 and 2002 will perform and survive (see thelisting on Page 15).

ALWAYS connect the primary positive leadfrom the terminal block to the master switchterminal or the positive battery terminal. Use8 AWG or larger chemical resistant wire andprotect with a loom.

Connect the ground lead from the chassis frameor the negative battery terminal to the groundstud located on the FoamPro 2001 and 2002foam pump assemblies. Use the same size wireas the power lead and bore metal connections.

DO NOT connect the main power leads to leadsthat are supplying some other device such as alight bar, siren or primer pumps.

CAUTION: The wires between the terminalblock, diode block and capacitor, as well as theinput power wire, are not protected by thesystem circuit breaker. Make sure these wiresare not damaged or short circuited.

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Figure 19. RFI/EMI Bead Installation

Figure 20. Extra Cable Storage

FLOWMETER AND CABLESThe flowmeter tee must be grounded. If metalpiping is used, sufficient grounding may bepresent. However, Victaulic joints, plastic pipeand rubber mounted pumps interfere withproper grounding and an additional groundstrap is required. Connect a braided groundstrap at least 1/4 inch [6 mm] wide from theflowmeter tee to the apparatus frame to ensureproper grounding. A #6-32 UNC tapped hole isprovided on the flowmeter tee for attaching theground strap.

Making round coils of extra control andflowmeter cables in the pump compartment canact as an antenna. While the flowmeter andcontrol cables cannot be shortened, variouslengths of cable are available to minimize the"extra" cable in the truck. (See the parts list inSection 13 for part numbers of different sizecontrol and flowmeter cables.) When routingcontrol and flowmeter cables, avoid routingthem next to antenna cables, radio power linesand radio components. When there is extracable, double the cable back on itself andsecure in a flat bundle with plastic wire tiesinstead of making a round coil (see Figure 20).

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MAKING SURE EVERYTHING IS WORKING RIGHT

SYSTEM POWER CHECKTurn the main power switch on the motor driverbox to ON and check the digital display readout— "HYPRO" should appear for a few secondswhile the computer checks itself (See Figure21); then, a zero should appear on the digitalreadout. If no zero appears, refer to the“TROUBLESHOOTING ” section for possiblecauses and solutions.

FOAM PUMP PRIMING CHECKTurn the CAL/INJECT valve to the CALIBRATEor FLUSH position. Provide a container to

Figure 21.Digital Display Control Module

Electrical❑ Tank level sensor is connected and the connections are sealed from moisture.❑ Digital Display Control Module connectors are correct and tight.❑ Cable connections at the motor driver box are correct and tight.❑ Flowmeter cable(s) properly connected to the Digital Display Control Module or MultiFlo as

required.❑ All cables and wires are secured and protected by loom from damage during operation.❑ RFI/EMI beads are installed; control and flowmeter cables are properly folded and secured;

radio antennas, power lines and equipment are away from the control and flowmeter cables.❑ All components, Digital Display Control Module, Flowmeter Tee, Pump Base, etc., are properly

grounded with adequate size wire and bare metal connections.❑ Adequate current capacity is available for the foam pump motor (see the listing on Page 15).❑ Circuit breaker switch on the motor driver box is in the ON position.

Liquid❑ Flowmeter is mounted with flow arrow in the correct direction for water flow.❑ Check valves are properly mounted in water and foam concentrate lines.❑ Strainer is properly mounted for the direction of concentrate flow in the foam tank to pump line.❑ Foam tank to the foam pump valve is in place and open.❑ Injector fitting lines are proper size and connections are tight.❑ CAL/INJECT valve is properly mounted and oriented for direction of concentrate flow.❑ The injector is in a common point to supply foam concentrate to all discharges specified to have

foam capability.❑ Fill foam tank(s) with a sufficient quantity of foam concentrate or water to allow system

calibration. Minimum of 5 gallons required .❑ Foam is properly primed.

FOAM PUMP❑ Foam Pump gear case filled to proper level with SAE 30 weight non-detergent oil.

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If you are still having difficulty priming the foampump in your FoamPro system, do thefollowing:

• Make sure foam concentrate tank shutoffvalve is open.

• Check to make sure there are no restrictionsfrom the concentrate tank to the inlet of thefoam pump.

• Check to make sure there are no leaks inthe plumbing where air can enter the pump.

Wet the foam pump to speed priming operationsusing the following procedures.

• Remove one of the valve caps from thehead of the pump and remove the checkvalve under it (see Figure 23).

• Pour a small amount of concentrate into thevalve opening to fill up the pumpingchamber in the pump head.

• Replace the check valve and cap andtighten securely. Run the pump again andthe pump should prime right away.

Proceed to calibration section as the systemmust be calibrated.

Figure 23. Foam Pump Manual Priming

Figure 22. Simulated Flow Indication

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collect the output that will be coming from thefoam pump.

• Put the system into “simulated flow mode”by selecting the “FLOW” display anddepressing "RESET" (both up and down

buttons simultaneously) (See Figure 22).Increase simulated flow by pressingbutton to permit easier priming (above 150).Display will show “ ” to indicate thesimulated flow.

• Engage the FoamPro system by pressingthe red “FOAM" button.

• Foam concentrate should begin flowing intothe container. If concentrate is not beingpumped, check first to make sure the foampump is running. If the pump is running, butno concentrate is being delivered, then thepump is most likely not primed completely.If the pump does not prime within 20-30seconds, disengage the system by pressingthe red “FOAM” button.

• If the system has been installed properly,foam concentrate should flow readily to thepump.

• Once foam flow is established, turn thesystem off and turn the CAL/INJECT valveback to the inject position.

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CALIBRATION AND SETUP• Enter the setup mode by pressing the

internal button on the left side of thecontroller.

• Enter the diagnostics mode by pressing theinternal button on the right side of thecontroller.

• The display will flash "CONF" and "DUAL.T"alternately.

• Press the DOWN button once. The displaywill now flash "CONF" and RSTART".

• Press the left internal button once. This putsyou back into the operational mode.

• Replace internal button screws and o-rings.

CALIBRATION AND SETUP MODECalibration and Setup is done by using theDigital Display Control Module function buttons.To enter or exit the calibration and setup mode,remove the cover screw and o-ring to the left ofthe display readout panel on the Digital DisplayControl Module (see Figure 24). Use a 3/32 inchAllen wrench to remove the screw and also tooperate the switch that is located beneath it.

To enter Calibration and Setup mode, use theAllen wrench to depress and release the switchinside the screw opening. The display will show“Elec Setup” until any function button is pressed.

Exit from Calibration and Setup mode isaccomplished by pressing and releasing theswitch again. The word “HYPRO” will appearfollowed by a zero after several seconds.REPLACE THE COVER SCREW AND O-RINGWHEN DONE.

CAUTION: ALWAYS REPLACE THE COVERSCREW AND O-RING TO KEEP WATER ANDDIRT FROM ENTERING THE DIGITALDISPLAY CONTROL MODULE OR SERIOUSDAMAGE TO THE COMPONENTS MAYOCCUR.

Figure 24. Calibration Switch Location

COVERSCREWTO BEREMOVED

SYSTEM SETUP PROCEDURESFoamPro systems permit easy calibration of thefoam proportioning unit to assure accurateoperation. The calibration process will makeadjustments to the flowmeter(s) and foam pumpdisplay readings.

NOTE: FoamPro systems can be calibrated toany unit of measure, i.e. U.S., Metric,Imperial, etc. It is necessary to use thesame unit of measure throughout thecalibration process to ensure properproportioning by the system.

IMPORTANT: Both the foam pump and flowmeter readings must be calibrated as a part ofthe initial setup after installation.

Recalibration should only need to be done aftermajor repairs or changes to the foam system.

SETUP FOR DUAL TANK OPERATIONThe FoamPro controller is factory defaulted tothe dual tank option. If you are installing aremote start/stop system, you must change thedefault setting for proper system operation. Theprocedure for this new setting starting from theoperational mode is as follows:

• Remove the screws to enter the setup anddiagonistic modes.

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SYSTEM RESETDuring calibration procedures, it may benecessary to return the system to the originalfactory default settings. To return to the factorydefault values, enter calibration and setup modeas previously described. Immediately afterentry into calibration and setup mode, prior topressing any other button, depress the and simultaneously. This action will return thesystem to the factory default settings. Proceedwith calibration and setup after performing this reset.NOTE: If using the Dual Tank Option on thecontroller and Reset is used, the Dual Tankdefault will need to be reconfigured.

FLOWMETER CALIBRATIONNOTE: It is critical that an accurate flowmeasuring device be used to measure thewater flow to calibrate the flowmeter(s). Use asuitable size smooth bore nozzle and anaccurate Pitot Gauge instrument. Hand heldpitot gauges are usually not very accurate. Atthe first available opportunity make sure thesystem is calibrated with an accurate flowmeasuring device. Determine the water flownormally expected from that flowmeterdischarge outlet. For example, actuallyestablish a flow of 150 gpm [568 L/min.] ofwater through a nozzle and Pitot system.

Enter Calibration and Setup mode using themethod previously described. Press the"SELECT" button and illuminate the light under“FLOW”. The current water flow rate will bedisplayed. Press the or button to set thereading to match the actual flow calculated fromthe Pitot gauge reading. Decrease fire pumppressure by approximately 1/2 and recalculatewater flow rate. Verify that reading on theDigital Display Control Module is the same asthe calculated value. Stop the water flow whenthe reading adjustments are completed.

To lock the settings, exit Calibration and Setupmode by depressing and releasing the switchinside the cover screw opening. The display willshow a zero until any function button is pressed.

SIMULATED FLOWThe default Simulated Flow value should beadjusted while operating in Calibration andSetup mode. Enter Calibration and Setup Modeusing the method previously described. Pressthe SELECT button until the light under FLOWis illuminated. Pressing both the and buttons simultaneously will display thedefault simulated flow reading. Adjust thesetting by pressing the or buttons to setthe desired rate, i.e., “ 100”. After the rate hasbeen set, press the and buttonssimultaneously again to return to Calibrationand Setup mode.

This setting will remain in the computer memoryand be the default rate for all future SimulatedFlow operations.

Exit Calibration and Setup mode as previouslydescribed.

FOAM CONCENTRATE INJECTION RATEWhen power is supplied to the FoamProsystem, the foam concentrate injection rate inmemory will be the default injection rate setting.The default concentrate injection rate can beadjusted by entering Calibration and Setupmode as previously described.

Use the SELECT button to illuminate the lampbelow “%”. The display will show the currentdefault concentrate injection rate stored in thecomputer memory as “PC x.x”. The orbuttons can be used to set the desiredconcentrate injection rate. Set this rate to thefoam concentrate injection rate used mostfrequently in operation.

Figure 25. Foam Concentrate Collection

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If using a dual tank system, each concentratecan be separately defaulted to the concentrateinjection rate individually, by selecting eithertank "A "or "B" on the electric selector switch orthe manual valve. The display will show PAx.x(Tank A) or Pbx.x (Tank B) depending whichtank is selected. Set the desired injection rateusing the or buttons. Using the electricselector switch or the manual valve switch to theother tank and set the desired injection rate forthat concentrate.

Exit the Calibration and Setup mode aspreviously described.

FOAM PUMP CALIBRATIONNote: The viscosity of different foamconcentrates may have an effect on the amountof foam concentrate that is injected into thewater stream. When calibrating the foam pump,use the foam concentrate that will be used mostfrequently during normal operations. Whendifferent viscosity foam concentrates are used,the actual concentrate injection may vary by asmuch as 10%. When using the dual tanksystem, each foam concentrate should alwaysbe calibrated individually. Select tank "A" or "B"on the electric selector switch or the manual valve.

Enter the Calibration and Setup Mode using themethod previously described. Press the SELECTbutton to illuminate the light below TOTALFOAM on the Digital Display Control Module.

Turn the “CAL/INJECT” valve pointer to the Cal/Flush position. Place a graduated measurecontainer beneath the outlet from theCAL/INJECT valve that can contain theexpected volume of foam concentrate (minimum5 gallons [19 liters]). If an accurate calibratedcontainer is not available, a scale can be usedto weigh the foam concentrate pumped. Thetotal volume of foam concentrate can then becalculated from this weight.

Start the FoamPro foam pump by pressing thered “FOAM” button. The foam pump will

operate and pump foam concentrate into thecontainer. Stop the foam pump and measureprecisely the amount of foam concentrate collected.

Adjust the reading on the Digital Display ControlModule to the volume pumped by pressing the or button. Repeat the procedure two tothree times to verify calibration.

If using a dual tank system, switch to the othertank by using the electric selector switch or themanual valve. Repeat the calibrating procedureusing the method previously described.

Turn the CAL/INJECT valve back to “INJECT”position.

Exit Calibration and Setup mode as previouslydescribed. REPLACE THE COVER SCREW.The system is now calibrated to the actual flowfrom the foam pump.

These Setup and Calibration procedurescomplete the adjustment of the system. TheFoamPro system is now ready to be placed inservice.

If this system is installed and calibrated by anapparatus manufacturer or dealer, the end usermay wish to adjust the default FoamConcentrate Injection Rate and/or SimulatedFlow to their special needs. These changescan be made without altering the calibration byusing the procedures for those functions only.

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PRESSURE RELIEF VALVEADJUSTMENTThe pressure relief valve is factory tested andpreset at 400 psi [28 BAR] (600 psi [41 BAR] formodel 2000HP). During normal installation andoperation, the relief valve will not requireadjustment. The following procedures areprovided if adjustment is necessary in fieldinstallation. DO NOT set the relief valve above400 psi [28 BAR].

Perform this adjustment after the foam pumphas been primed.1. Determine the maximum pressure that will

be needed to discharge foam solution. (Forexample: The maximum foam injectionpressure should be approximately 50 psi[3.5 BAR] higher than the maximumoperating pressure as set forth bydepartment policy.)

2. Gather the items required for readingconcentrate injection pressure: a 0-500 psi[0 to 34.5 BAR] test quality gauge, 500 psi[34.5 BAR] hoses and fittings to connect tothe injector line from the foam pump.

3. Disconnect the injector from the foam lineand connect the pressure gauge to it.

4. Screw the Pressure Adjustment Nut on topof the valve all of the way down until it stops.

5. Unscrew the Pressure Adjustment Nutcounterclockwise 10 full turns. This will placeit in a position to relieve at low pressure.CAUTION: DO NOT run the FoamPro 2001or 2002 system more than one minute deadheaded against the pressure gauge becausethe foam pump will overheat.

6. Operate the foam pump as described in theFoam Pump Priming Check Section.

7. While the foam pump is running, slowlyscrew the Pressure Adjustment Nut downclockwise until the desired pressure isreached. Apply tamper proof type sealant topressure relief valve adjustment nut so that itdoes not move accidentally.

8. Stop the foam pump.WARNING: Slowly loosen the foam pressureline fittings and allow the pressure to escape.Protect your face and eyes from anypotential spray which may occur.

9. Reconnect the foam line to the injectorfitting. The pressure relief valve is now set.

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OPERATING INSTRUCTIONSthe water flowmeter will display the current flowrate of the water.

If water flow requirements exceed the capacityof the pump to deliver foam concentrate, thepump will run at maximum rate and “HI FLO”will flash on the Digital Display Control Moduleso the operator realizes that the systemcapacity is being exceeded.

If the flow decreases such that the requiredinjection rate is less than the lowest rating of thepump, the pump will run at its minimum rate and"Lo.Flo" will flash on the display so the operatorwill know the system is running rich on foampercentage.

DISPLAY INFORMATIONThe five digit display on the Digital DisplayControl Module shows the value of the selecteddisplay function or provides warnings to the

Figure 26. Digital Display Control Module Operation

NORMAL SYSTEM OPERATIONOnce the system has been set up andcalibrated, operation is very simple and iscontrolled by the buttons on the Digital DisplayControl Module (see Figure 26). For setup andcalibration instructions, see Section 9.

When the “FOAM” button is pressed, the “ON”status lamp will illuminate, indicating that thesystem is ready. The “ON” status lamp will flashwhen foam is being injected. The FoamProsystem will monitor the water flows and controlfoam injection at the specified concentrateinjection rate. The system responds tovariations in water flow by increasing ordecreasing the speed of the foam pump. Whenthe "FOAM" button is again pressed, the “ON”status lamp will extinguish, indicating that thesystem is in Stand-By mode and the pump willstop but other system monitoring functions willcontinue. Without foam concentrate injection,

Status LampsON — Run/Stand-By statusFLOW — Water flow rateTOTAL WATER — Total water flowed% — Foam flow percentageTOTAL FOAM — Total concentrate flowed

Up Arrow ( )Increase value shown

SELECTSelect Display Functions

FOAMTurn FoamProsystem ON/OFF

10

➯➯Down Arrow ( )

Decrease value shown

HYPRO

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operator when the system is operating. Afunction is selected by pressing the grey“SELECT” button in the upper right hand cornerof the Digital Display Control Module. Eachtime the button is pressed, a new function modeis selected and displayed. A LED lamp abovethe digital display denotes which function isbeing displayed. Pressing the SELECT buttonchanges the value displayed but does not altersystem operation.

The Display Functions include:FlowThe display shows the current flow rate ofwater or foam solution per minute.

Total WaterThe display shows the total amounts ofwater or foam solution pumped. Thistotalized value may be reset. See "ResetFunctions" paragraph.

% (Percent)The display will show the foam concentrateinjection rate setting in the % mode.

Total FoamThe display shows the total amount of foamconcentrate pumped. The value will be inthe same unit of measure as the water flow.This totalized value may be reset. See"Reset Functions" paragraph.

RESET FUNCTIONSThe totalized values for water and foamconcentrate pumped can be cleared frommemory by performing a RESET function.Using the “SELECT” button, select either“TOTAL WATER” or “TOTAL FOAM”. Bypressing and holding both the andbuttons at the same time, the value shown iscleared and displayed as zero.

FOAM PERCENTAGE (%)When the concentrate percentage (%) isselected, the and buttons will respectivelyincrease or decrease foam concentratepercentage. The percentage can be changedanytime during normal operation. Whenever the or buttons are momentarily pressed, the

display will switch to the “%” display and showthe current percentage that is set, in any displaymode. If either button is held down for a periodof 2 seconds, the value will increase ordecrease accordingly. Once released, thedisplay will return to the last selected display.When a reset is performed in the % displaymode (pressing both the and buttons atthe same time) the foam concentrate injectionrate is returned to the default value. The defaultvalue is set during calibration.

DISPLAY MESSAGESSeveral safety features are provided to protectthe foam concentrate pump and the electricmotor.

Low Foam Tank LevelThe pump is interlocked with the foamconcentrate tank level switch. If the tank isempty, the pump will not run for more than2 minutes. A low foam concentrate tank level isdenoted by “Lo Con” blinking on the display.This code will alternate with the normal displayvalue shown. If two consecutive minutes of lowconcentrate level is detected, the display willshow “No Con”, the pump will stop, and thesystem will go to Stand By mode until the foamlevel is restored and the on button is depressed.

Pump ErrorMotor stall protection is provided. In the eventthat the pump motor will not run or stalls for10 seconds, the display will show “ERR.EL” toindicate that the pump is producing no feedbackto the control signal. The system will return tooff status to protect the electric motor andcomponents.

High/Low Flow ConditionWhenever the foam pump cannot reach theselected level an indication of the status willblink in the background as:“Lo.Flo” – Foam delivery rate is below pumpcapability.“Hi.Flo” – The water delivery rate is too high forthe foam pump's capacity.

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Normal Operation Summary

How to

1. Turn FoamPro system on.

Action

1. Operate the apparatus engine todevelop hydraulic pressure. Turnthe FoamPro Main Power circuitbreaker switch on. HYPRO willappear on the displaymomentarily.

2. Make foam solution.

3. Read the total amount of waterflowed during the operation.

4. Read % of concentrate.

5. Change the % of concentrate.

Display

2. Establish water flow to the foamcapable discharge. The DigitalDisplay Control Module willindicate the water flow rate. Pressthe FOAM button (red upper-leftbutton). The LED lamps belowthe ON and FLOW labels willilluminate and the lamp below theON label will flash. The rate ofwater flow will be displayed inunits per minute.

3. Press the SELECT button (greyupper-right button) until the LEDlamp below the TOTAL WATERlabel is illuminated. The totalamount of water will be displayed.Reset this value to zero bypressing the � and � buttons atthe same time.

4. Press the SELECT but ton(grey upper-right button) untilthe LED lamp below the %l abe l i s i l luminated. Thedisplay will read percentageof foam concentration. Foamwill continue to be injected.

5. Press the button beside the �or �. The display will show thenew concentrate injection ratechosen. The propor tion ofconcentrate injected will changeimmediately.

Normal Operation Summary Continued on Next Page

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Normal Operation Summary

How to Action

6. Press the SELECT button (greyupper-right button) until the LEDlamp below the TOTAL FOAMlabel is illuminated. The totalamount of foam concentrateused will be displayed. Reset thisvalue to zero by pressing the �and � buttons at the same time.

8. Turn the FoamPro system off.

Display

7. If on, press the FOAM button, thefoam injection will stop. Press theSELECT button (grey upper-rightbutton) until the LED lamp belowFLOW is illuminated. The waterflow rate through the foamdischarge(s) will be displayedwhether foam is being pumpedor not.

8. Turn the apparatus Master orBattery switch off. The systemcan also be turned off by usingthe circuit breaker switch on thevalve driver box.

6. Read the total amount of foamconcentrate used.

7. Read water flow without foaminjection.

NOTE: Any of these changes canbe made at anytime during, before,or after water is flowing.

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Simulated Flow OperationThe Simulated Flow function of the system allows theoperator to control the foam pump manually. The waterflow rate and the concentrate injection percentage ratecan be set by using the display readout and the rateadjustment buttons on the Digital Display Control Module.This function provides the manual control requirement ofNFPA. This function also allows the operator to emptythe foam concentrate tank for cleaning or changing foamtypes. It also provides a means of checking the operationof the foam pump at all normal rates of flow and injectionwithout running the water pump.

Warning: When operating the FoamPro in theSimulated Flow function, an outlet for the foamconcentrate injection must be provided. Otherwise,dangerous excessive pressure may be built up in theapparatus water piping and or hoses. This outlet forthe foam concentrate can be provided by turning theCAL/INJECT valve to the CAL position. A suitablecontainer must be provided to collect the foamconcentrate.

Simulated Flow Operation Summary

How to Display Action

1. Make sure the lamp belowFLOW is illuminated. Press boththe � and � buttons at thesame time. The FoamProDisplay will read to the leftof the flow, meaning the systemwill “simulate” the displayedwater flow rate. (The defaultvalue of flow may be set to anyvalue, see Section 11).

CAUTION: Be certain that an out-let is provided for the foam con-centrate when the foam pump isstarted.

2. Press the SELECT button(grey upper-right button) untilthe LED lamp below the %label is illuminated. The displaywill read the current percentsetting. Press the � or �

buttons to select the desiredinjection rate. The FoamPro willrespond and immediatelybegin injecting concentrate atthe new rate.

1. Begin Simulated FlowFunction.

2. Change the injection rate whilein Simulated Flow Function.

3. Change the Simulated FlowRate while in the SimulatedFlow Function.

Simulated Flow Operation Summary Continued on Next Page

3. Press the SELECT button (greyupper-right button) until theLED lamp below the FLOWlabel is illuminated. The displaywill show and current flowrate. Press the � or � to selectthe desired simulated waterflow rate. The FoamPro willrespond and immediately beginoperating at the new flow rate.

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Simulated Flow Operation Summary

How to Display Action

4. Place a suitable container underthe CAL/FLUSH outlet tube.Place the CAL/INJECT valve inthe CAL/FLUSH position. Pressthe FOAM button. The foampump will operate and foamconcentrate will be dischargedfrom the outlet tube.

NOTE: FoamPro must be inSimulated Flow Mode.

5. Press both rate adjustmentbuttons at the same time. The symbol will leave the displayand the FoamPro will operateautomatically from the flowsensor signal. Turning theapparatus Master or Batteryswitch off will also turn off theSimulated Flow Function. Thenext time the power is turnedon, the FoamPro will return tothe original automatic defaultsettings.

4. Empty the Foam Tank.

5. Turn the Simulated FlowFunction off and return toautomatic operation.

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PRIMING THE FOAM PUMP WHEN FOAMTANK HAS RUN DRY

In some instances, the foam tank may run drywhile operating the FoamPro system. The foampump is designed to pump liquid. When the firepump is running, the foam pump cannot pumpair efficiently against 100 to 150 psi backpressure. To re-establish foam concentrate flowquickly, the following procedure can be used.

MAINTENANCE1. Monthly: Inspect wiring, hoses, flow meters,

and connections for tightness, corrosion,leaks and/or damage.

2. Monthly: Remove and clean the foamstrainer screen(s). Flush as required.

3. Monthly: Check foam pump gear case oillevel and refill as necessary withSAE 30 weight non-detergent oil.

4. Annually: Drain the pump oil and refill pumpcrankcase with SAE 30 weight non-detergent oil. Check for concentrate orwater in the drain oil.

NOTE: Water quality, flushing & storagetechniques, environment and usage may havean effect on your maintenance schedule. Toensure equipment longevity, it is recommendedto adjust your schedule accordingly.

CAUTION: Release all pressure and drain allconcentrate and water from the dischargesystem before servicing any of its componentparts.

Figure 27. Foam Pump Oil Level Check

1. Turn the CAL/INJECT valve to the Calibrateposition.

2. With the fire pump flowing water from foamdischarge and the FoamPro on observe thehose from the CAL/INJECT valve.

3. When foam concentrate flows from the unitturn the CAL/INJECT valve back to theINJECT position. The pump is now primedand ready for normal operation.

4. If the fire pump is not running, place theFoamPro into the simulated flow mode andproceed with above steps.

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These FoamPro systems are designed to be easy to diagnose and service. There are severalmajor components. Servicing the system involves isolation of the failed component and replacingit. There are no user serviceable internal components. Due to the reliable nature of modernelectronics, most failures are traced to faulty cables or wiring problems. A diagnostic mode is builtinto the system to help isolate problems.

TROUBLESHOOTING


ENTERING DIAGNOSTIC MODEDiagnostic mode is entered by removing thecenter screw and o-ring on the right hand sideof the Digital Display Control Module (seeFigure 28) using a 3/32 inch Allen wrench. Oncethe screw is removed, press and release theswitch located under the screw.

To exit the diagnostic mode, press and releasethe switch again. The word "HYPRO” willappear on the display followed by a zero afterseveral seconds. REPLACE THE COVERSCREW AND O-RING WHEN DONE.

COVER SCREWTO BEREMOVED

Figure 28. Diagnostic Switch Location

12

HELLO

HYPRO

35



NOTE: ALWAYS REPLACE THE COVERSCREW AND O-RING TO KEEP WATER ANDDIRT FROM ENTERING THE DIGITALDISPLAY CONTROL MODULE BECAUSE ITCAN CAUSE SERIOUS DAMAGE TO THECOMPONENTS.

The system will provide a full complement ofdiagnostic functions to enable verification of allsystem components. Refer to the electricaldiagram in Figure 33.

DIAGNOSTIC MODE FUNCTIONSOn entry to diagnostic mode, the display willshow “HELLO”. No other status indicator lightswill be illuminated. “SELECT” will select thevarious modes, each indicated by the statusindicator light by the label. These diagnosticmodes include:

“None”Pressing will illuminate all displaysegments and status indicator lights.

“Flow”The value shown is the current number offlow pulses being received each second. Ifno water is flowing, the value should bezero. This is a function test for theflowmeter. Removing the flowmeter sensorfrom its tee and spinning the paddlewheelshould produce a reading other than zero onthe display. If there is no reading on thedisplay, connect the sensor directly to theback of the Digital Display Control Module.This test will determine if the flowmetersensor or extension cable is defective.

“Total Water”The value shown reflects the level of theliquid foam concentrate in the tank.“Lo.Con” indicates that the tank is empty.“Hi.Con” indicates a satisfactory level foroperation. This is a test of the low tank levelsensor and wiring.

“%” (Percent)The value shown reflects the duty cycle torun the foam pump. If “FOAM” is pressed,the pump will be run at the selected rate andthe “ON” status indicator lamp will beilluminated. The value may be altered with or . This is a test of the motor controlbox and pump hook up. Depressing thewill increase pump speed, which should beaudible and visible on the “TOTAL FOAM”display.

“Total Foam”The value shown is the current number ofpump pulses being received each second.If the pump is not running, the value shouldbe zero. Increasing motor speed in "%"mode should increase displayed value. Thisis a test of the pump feedback sensor andwiring.

➯

➯

➯

➯

36



Symptom Probable Cause(s) Corrective Action

Pump runs but produces no flow Pump is not primed. See Foam Pump Priming Check section on Page 21.

Pump loses prime, Air leak in suction hose or inlet fittings. Remove suction hose and test for leaks bychattering noise, pressure fluctuates. pressurizing hose with water. Make sure thread

sealant has been used on all fittings.

Suction line is blocked, collapsed or Remove suction line and inspect it for a loosetoo small. Iiner or debris lodged in hose. Avoid all

unnecessary bends. Do not kink hose.

Clogged suction strainer. Clean strainer.

Pump runs for 8 to 10 seconds then Speed sensor circuit open. Inspect wiring and connection to speed sensorshuts down. ERR.EL may be flashed ondisplay. Sensor position incorrect. Check to ensure that the speed sensor is within

the proper sensing distance of .005 to .015 inchesfrom the pulley teeth.

Speed sensor not functioning. Replace speed sensor.

Inadequate ground or voltage. Check connections & voltage.

Pump runs full speed whenever the Poor ground to motor driver box on pump/motor Make sure screws are tight and a good groundcircuit breaker switch is in “ON”. bracket. is maintained.

No characters are displayed on the Note: The main switch is current limiteddigital display. to 41 amps for System 2001/12V DC;

56 amps for System 2002 & 2002HP/12V DC;22 amps for System 2001/24V DC;30 amps for System 2002/24V DC.

The main power switch is not “ON”. Turn on the main power switch on thecomputer control module.

Cables not correctly connected. Inspect and secure connections.

Control cable(s) defective. Replace control cable(s)

Digital display has been damaged. Replace the digital display.

Inadequate ground or voltage. Inspect connections & check voltage.

System is powered up and the Foam No water is flowing in any of the foam discharges. Flow water.ON/OFF switch has been pressed butthe foam pump doesn’t run. Flow meter wiring not correct. Inspect wiring and connection to flow meter.

Flow meter obstructed. Clear flow meter of debris.

Flow meter not functioning. Replace flow meter.

Float is on plunger wrong–indicating tank is low. Remove the snap ring at the top of the plungerand remove the float, turn it over and reinstall.

Float stuck on plunger–indicating tank is low. Inspect and clean float switch.

Control cable(s) defective. Check connections and replace control cable(s)

TROUBLESHOOTING GUIDE

37



System returns to standby mode Insufficient power supply. Inspect and correct power and groundwhile pumping or HYPRO appears connections, and wiring.momentarily while pumping.

Current resistance in wiring circuits. Make sure 8 AWG (minimum) wire is usedfor connection to battery terminal.

LO.CON appears on display. Concentrate level in tank is low. Fill concentrate tank.

Low tank level sensor or wiring is inoperative. Repair or replace defective components.

ERR.SU on power up. Set up parameter memory is not functioning. Contact HYPRO for replacement. (NOTE: This unitwill continue to operate using factory set upvalues.)

Display shows “?” for flow. Flowmeter is sensing water flow, but the flow Check flowmeter.rate is too low for precise proportioning.

CAL/INJECT valve is leaking Valve seat is loose. Remove hose and fitting from inject portof valve and tighten seat using 3/8 inch hex wrench.Reconnect fitting and hose.

System cannot be calibrated Calibration values selected are out of range Perform system reset as described inof system or setup memory is full. Calibration Section.

Symptom Probable Cause(s) Corrective Action

TROUBLESHOOTING GUIDE (Cont'd.)

38



PARTS IDENTIFICATION FOR SYSTEM 2001

Ref. Part No. Description Qty.1 2341B-P-01 Foam Pump Assembly-2001 12 3300-0092 Relief Valve 13 3304-0025 Cal/Inject Valve 14 2404-0271 Reducer 15 2401-0038 1/2 inch NPT Tee 16 3350-0135 Line Strainer (3/4 inch NPT) 17 0704-8600A1 Flange Adaptor 18 2530-0064 Speed Sensor 19 2738-2003 Coupling Body 3/4 inch [19 mm] 1

10 2728-0001 Rubber Disc 111 2738-2002 Coupling Body 5/8 inch [16 mm] 112 3115-0029 Gear 113 2570-0011 Electric Motor (1/2 hp; 12 V) 113 2570-0020 Electric Motor (1/2 hp; 24 V) 114 2840-0071 Shield 115 2527-0067 Digital Display Control 116 2530-0096 Terminal Block 118 2527-0071 Motor Driver Box 1

Ref. Part No. Description Qty.19 1700-0120 Grommet 120 1450-0010 Plastic Cap 121 2910-0011 Clamp, Vinyl Coated 222 2530-0061 Capacitor (82,000uF) 123 1510-0086 Mounting Bracket 124 2404-0182 Injector Fitting 125 2510-0028 Tank Level Sensor (Vertical) 1

2510-0032 Tank Level Sensor (Side) 126 2520-0048 Control Cable (6 ft. [2 m] Lg) 1

2520-0049 Control Cable (12 ft. [3 m] Lg) (Std) 12520-0050 Control Cable (20 ft. [5 m] Lg) 1

27 2520-0042 Tank Sensor Cable 128 2520-0045 Flowmeter Cable (6 ft. [2 m] Lg) 1

2520-0046 Flowmeter Cable (12 ft. [3 m] Lg) (Std)12520-0047 Flowmeter Cable (20 ft. [5 m] Lg) 1

30 3430-0351 RFI Kit for Controller (4 pcs) 13430-0353 RFI Kit for Flowmeter (4 pcs) 1

31 6032-0012 Placard32 3320-0027 Check Valve, 1/2 inch 1

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Ref. Part No. Description Qty.1 2345B-P-08 Foam Pump Assy-2002 11 2331B-P-01 Foam Pump Assy-2002HP 12 3300-0092 Relief Valve 13 3304-0025 Cal/Inject Valve 14 2404-0271 Reducer 15 2401-0038 1/2 inch NPT Tee 16 3350-0135 Line Strainer (3/4 inch NPT) 17 0704-8600A1 Flange Adaptor 18 2530-0092 Speed Sensor 19 2738-2003 Coupling Body 3/4 inch [19 mm] 1

10 2728-0001 Rubber Disc 111 2738-2002 Coupling Body 5/8 inch [16 mm] 112 3900-0049 Gear 113 2570-0016 Electric Motor (.75 hp; 12 V) 113 2570-0017 Electric Motor (.75 hp; 24 V) 114 2840-0071 Shield 115 2527-0067 Digital Display Control 116 2530-0097 Terminal Block 117 2527-0031 Diode Block Assembly 118 2527-0069 Motor Driver Box 119 1700-0120 Grommet 1

Ref. Part No. Description Qty.20 1450-0014 Plastic Cap 121 2910-0016 Clamp, Vinyl Coated 222 2530-0087 Capacitor (154000uF) 123 1510-0086 Mounting Bracket 124 2404-0182 Injector Fitting 125 2510-0028 Tank Level Sensor (Vertical) 1

2510-0032 Tank Level Sensor (Side) 126 2520-0048 Control Cable (6 ft. [2 m] Lg) 1

2520-0049 Control Cable (12 ft. [3 m] Lg) (Std) 12520-0050 Control Cable (20 ft. [5 m] Lg) 1

27 2520-0042 Tank Sensor Cable 128 2520-0045 Flowmeter Cable (6 ft. [2 m] Lg) 1

2520-0046 Flowmeter Cable 1(12 ft. [3 m] Lg) (Std)

2520-0047 Flowmeter Cable (20 ft. [5 m] Lg) 129 1450-0012 Plastic Terminal Protector 130 3430-0351 RFI Kit for Controller (4 pcs) 1

3430-0353 RFI Kit for Flowmeter (4 pcs) 131 6032-0012 Placard32 3320-0027 Check Valve, 1/2 inch 1

PARTS IDENTIFICATION FOR SYSTEM 2002

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(Please make a photocopy for your use.)

14 INSTALLATION DRAWINGS

FOAM

RESET

SELECTON FLOW TOTAL WATER TOTAL FOAM%

0.21 Inch Dia. Hole Apparatus Panel

1.75 in.(44.5 mm)

4.25 in.(108 mm)

3.50 in.(89 mm)

1.75 in.(44.5 mm)

3.70 in.(94 mm)

Dia.

2.75 in.(70 mm)

3.50 in.(89 mm)

Cutout Dimensions for Display Control Module

Display Requires 3-7/8'' [98 mm] Dia. Hole

Cutout Dimensions for System Spec. Placard

41



Assy. Part A B C D Maximum Accuracy Maximum Operating

Number Flow Range (gpm) Flow Range (gpm)

2660-0030 1-1/2''—11-1/2'' NPT 2'' Pipe 7-3/8'' [188 mm] 3-7/8'' [99 mm] 5-110 3-145

NOTE 1'' I.D. Bore

2660-0031 1-1/2"—11-1/2" NPT 2" Pipe 5-3/8" [137 mm] 4-1/8" [105 mm] 10-320 3-380

2660-0031B 1-1/2"—11" BSP 2" Pipe 5-3/8" [137 mm] 4-1/8" [105 mm] 10-320 3-380

2660-0032 2"—11-1/2" NPT 2-1/2" Pipe 5-3/8" [137 mm] 4-3/8" [111 mm] 15-520 5-625

2660-0032 2"—11" BSP 2-1/2" Pipe 5-3/8" [137 mm] 4-3/8" [111 mm] 15-520 5-625

2660-0033 2-1/2"—8" NPT 3" Pipe 5-3/8" [137 mm] 4-9/16 [116 mm] 20-750 8-900

2600-0033B 2-1/2"-11" BSP 3" Pipe 5-3/8" [137 mm] 4-9/16 [116 mm] 20-750 8-900

2660-0034 3"—8" NPT 4" Pipe 5-1/2" [140 mm] 4-7/8 [124 mm] 30-1150 12-1380

2600-0034B 3"—11" BSP 4" Pipe 5-1/2" [140 mm] 4-7/8 [124 mm] 30-1150 12-1380

2600-0035 4"—8" NPT 5" Pipe 5-1/2" [140 mm] 5-3/8" [137mm] 55-1980 20-2380

2660-0035B 4"—11" BSP 5" Pipe 5-1/2" [140 mm] 5-3/8" [137mm] 55-1980 20-2380

NOTES: 1. Use CAUTION not to damagesensor during assembly.

2. Use Loctite PST 565 orequivalent Teflon tape to sealpipe threads.

3. Maximum horizontal installationangle to allow proper waterdrainage. Unit may also beinstalled in vertical pipingarrangement.

* = Minimum sensor service clearance.

FoamPro Flowmeter

42



43



44



Hypro Corporation, as supplier of FoamPro, warrants to the original purchaser, each new pump, system or other product of its ownmanufacture, for a period of one year from the date of shipment from the factory, to be free from defects in material and workmanshipunder normal use and service. “Normal use and service” means not in excess of recommended maximum speeds, pressures, andtemperatures, or handling fluids not compatible with components materials, as noted in applicable Hypro Corporation productcatalogs, technical literature, and instructions. This warranty shall not apply to any pump, system or other product which shall havebeen repaired or altered to adversely affect the performance or reliability of the pump, system or other product.

Neither this warranty nor any implied warranty apply to damage or harm caused by any or all of the following: (1) Freight damage; (2)Freezing damage; (3) Damage caused by parts and/or accessories or components not obtained from or approved by HyproCorporation; (4) ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES, OTHER THAN INJURY TO THE PERSON, ARISING FROMTHE USE OF ANY PUMP OR OTHER PRODUCT MANUFACTURED BY HYPRO CORPORATION EXCEPT in states that do notallow the exclusion or limitation of incidental or consequential damages; (5) Damage due to misapplication and/or misuse; (6) Normalwear of moving parts or components affected by moving parts.

The liability of Hypro Corporation under the foregoing warranty is limited to the repair or replacement at Hypro Corporation’s optionwithout charge for labor or materials of any parts upon return of the entire pump, system or other product or of the particular part to theHypro Corporation factory within the warranty period, at the sole expense of the purchaser, which part shall upon examination appearto Hypro Corporation’s satisfaction to have been defective in material and workmanship.

The liability of Hypro Corporation under any theory of recovery (except any express warranty where the remedy is set forth in theabove paragraph) for loss, harm or damage, shall be limited to the lesser of the actual loss, harm or damage or the purchase price ofthe involved pump, system or other product when sold by Hypro Corporation to its customer.

Hypro Corporation expressly warrants its pumps and other products as above stated. THERE ARE NO OTHER EXPRESSWARRANTIES. ANY IMPLIED WARRANTIES, INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR APARTICULAR PURPOSE, ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF PURCHASE BY THE ORIGINALPURCHASER EXCEPT in states that do not allow time limitations on implied warranties. THERE IS NO IMPLIED WARRANTY OFFITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY WHEN THIS PRODUCT IS PUT TO RENTAL USE.

No person including any dealer or representative of FoamPro is authorized to make any representation or warranty concerning HyproCorporation's FoamPro products on behalf of Hypro Corporation, or to assume for Hypro Corporation the obligations contained in thiswarranty. Hypro Corporation reserves the right to make changes in design and other changes and improvements upon its productswithout imposing any obligations upon itself to install the same, upon its existing products then in process or manufacture.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

IMPORTANT NOTICEIt is imperative to package all FoamPro components properly, before shipment (with Return GoodsAuthorization attached) back to Hypro Corporation. The FoamPro contains electronic components that mayreceive damage from improper shipping procedures! All FoamPro components shipped back to Hypro willpass through Quality Control Inspection, and will be photographed after the box is opened. Any shippingdamage, such as superficial scratches, nicks, etc., to the unit makes it unusable (even after the internalwarranty problem is repaired) and thus must be refinished to “like-new” condition during the warrantyprocess. You are responsible for any physical damage occurring to FoamPro components at your facility andduring shipment back to Hypro.

Package the FoamPro, complete with all the recommended parts the Customer Service representativerequires (i.e., Digital Display control with all premolded wire cables etc.) in its original carton with theStyrofoam and other packaging materials, as it was received at your facility.

Hypro Corporation appreciates your attention in this matter, as we feel it will help us to serve you in a betterfashion, while keeping the cost of the FoamPro product competitive. Thank you.

WARRANTY15

Documents

Systems 2001, 2002 and 2002HPpneumaxcafs.com/manuals/Support Docs/FoamPro...Systems 2001 and 2002 A QUICK LOOK AT HOW THE SYSTEM WORKS The FoamPro 2001 and 2002 systems are electric