ESS SFoam User manual

ESS Sfoam Dust Suppression 1 14/06/2021
ESS SFoam
Dust Suppression Foam Generation Units
Installation/ Operations Manual

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National OfficeDetails
Location
Address
Phone & Email
CURRUMBIN
11 –13 Traders Way
PO Box 121
Currumbin QLD 4223
[phone]
[e-mail]
GLADSTONE
Unit 2/34 Chapple Street
PO Box 1475
Gladstone QLD 4680
[phone]
[e-mail]
KALGOORLIE
Unit 1/ 182 Boulder Rd
Kalgoorlie WA 6430
PO Box 10471
Kalgoorlie WA 6433
[phone]
[e-mail]
KARRATHA
26 Midas Road
Malaga WA 6090
[phone]
[e-mail]
MACKAY
1 Progress Street
Paget, QLD 4740
PO Box 5755
Mackay Mail Centre QLD
4741
[phone]
[e-mail]
MAITLAND
Unit 2 Barton Court 6
Johnson Street
Maitland NSW 2320
[phone]
[e-mail]
PERTH
26 Midas Road
Malaga WA 6090
[phone]
[e-mail]
TOWNSVILLE
Unit 4/ 585 Ingham Rd
Mt St John
Townsville QLD 4818
[phone]
[e-mail]
SOUTH AUSTRALIA
38 Montpelier Terrace Port Elliot
SA 5212
0408 948 175
[e-mail]
VICTORIA
Unit 4 / 238 Governor Road
Braeside VIC 3195
[phone]
[e-mail]
WOLLONGONG
Unit 1 / 20 Doyle Avenue
PO Box 343
Unanderra NSW 2526
[phone]
[e-mail]
TOLL FREE 1800 074 446 FROM ANYWHERE IN AUSTRALIA
VSS TOLL FREE 1800 300 877

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WARRANTY NOTE
ESS WARRANTS the ESS SFoam to be free of defects both in materials and workmanship
for a period of 12 months from the date of despatch of the product from the ESS factory.
The warranty given by ESS in this regard will extend only to replacing or repairing product
shown to be defective.
The warranty also is subject to the following restrictions:
(a) Installation of the product contrary to the instructions contained in the supplied manual
will void such warranty absolutely;
(b) The warranty will not extend to any liability for injuries incurred and which result from
the use of the product contrary to the instructions in the manual;
(c) Save as prescribed by law, ESS will not be liable for any damage sustained by a
purchaser or a third party by way of consequential loss arising out of defects in the
product.
You are asked to note that ESS offers purchasers a service whereby either:
(a) It will install the product and certify the correctness of such installation, or
(b) Certify the correctness or otherwise of the installation of the product by third parties.
This certification service is designed to ensure that you obtain the full benefit of the ESS
warranty hereby provided. If you would like to take advantage of the installation certification
service provided, please contact ESS regarding the service.
Refer to the Final Checklist at the back of this manual.
Visit the ESS website www.esseng.com.au to register your product warranty.
THE CONTENTS OF THIS MANUAL ARE COPYRIGHT TO:
ESS ENGINEERING SERVICES AND SUPPLIES PTY LTD
ALL RIGHTS RESERVED
Information contained herein is for use in the operation of the ESS SFoam, purchased from
ESS and cannot be passed on to any other party without express permission, in writing, from
ESS.

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INDEX
SECTION 1
SCOPE
SECTION 2
INSTALLATION
SECTION 3
START UP & COMMISSIONING
SECTION 4
SHUT DOWN
SECTION 5
TROUBLE SHOOTING
SECTION 6
MAINTENANCE
SECTION 7
APPENDIXES
SECTION 8
FINAL CHECKLIST

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SECTION 1 –SCOPE
This manual details the installation, operation and maintenance requirements for the ESS SFoam
Senior and SFoam Junior standard units as well as associated hardware such as expansion pots
and spray nozzles. This equipment is designed to produce foam of consistent properties which can
be used as a dust suppressant.
PRINCIPLE OF OPERATION
The SFoam dosing process is activated by the energizing of two solenoid valves which control the
flow of compressed air and water. The solenoids can be controlled by manual switching or in
automatic mode via a remote signal.
The flow of water initiates the operation of the dosing feeder which then injects the SFoam dust
suppression chemical in to the water line. The solution concentration can be manually adjusted at
the dosing feeder head between 0.2% and 1.6% concentration. As the dosing feeder is of the
proportioning type, the solution concentration will remain constant even if the water flow rate
fluctuates.
Pressure regulators are installed on both the air line and the solution line.
The foam is activated in an expansion chamber which is capable of supplying foam to up to six
dosing points. The SFoam Junior is capable of supplying on to two chambers whilst the SFoam
Senior is capable of supplying two to three chambers (depending on line distance and pressure
constraints).
Refer to Fig. 1 for a schematic of a typical system.
Fig. 1 Schematic of a typical SFoam Application

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Fig 2 SFoam Senior Unit
Fig SFoam Junior Unit

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Supply Ports to
Dosing Points
Expansion Chamber
Air and Solution
Rotameters (FlowMeters)
Air and Solution
Flow Control
Valves
Fig 4 SFoam Expansion Chamber
Fig 5 Type A Nozzle Mounting Bracket Fig 6 Type b Nozzle Mounting Bracket

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SECTION 2 –INSTALLATION
Services Required
Electrical: 90 to 260Vac, 50/60 Hz, single phase.
Water: SFoam Junior. 10 –40 litres/min @ 410 kPa Min.
SFoam Senior. 10 –75 litres/min @ 410 kPa Min.
Compressed Air: SFoam Junior. 25 - 75 cfm @ 75 psi Min.
(12 to 35 l/sec @ 520 kPa Min).
SFoam Senior. 25 - 150 cfm @ 75 psi Min.
(12 to 70 l/sec @ 520 kPa Min).
WARNING: The recommended minimum water and air pressures are extremely important. If a
minimum of 410 kPa water pressure and 75 psi air pressure cannot be achieved then foam
distribution and quality will be severely affected. However, if the expansion chambers are
installed 5 metres or more above the SFoam unit then higher supply pressures will be
required. As a “rule of thumb”, water pressure should be increased 50 kPa for every 5 metres
of elevation.
Expansion Chambers
SFoam Junior: Depending on line distances and pressure constraints, the
SFoam Junior is capable of supplying one or two chambers
SFoam Senior: Depending on line distances and pressure constraints, the
SFoam Senior is capable of supplying two to three chambers.
Pre-Installation Check List
Ensure that the water supply is reliable adequate and of the correct quality. A
booster pump may be required. Note: A minimum water pressure of 410
kPa is required.
Ensure that the compressed air supply is reliable, adequate and of the
correct quality. Note: A minimum pressure of 75 psi is required.
Ensure that either a 90 to 260Vac, 50/60 Hz, single phase supply is
available.
Ensure that the electrical protection is adequate. Other protection classes
are available upon request. Are there any other site specific electrical
requirements?
Ensure that the proposed site for the SFoam Junior/Senior has good access
for the installation/removal of chemical drums or totes of SFoam and is
(preferably) centrally located between the foam application points.
Expansion chambers must be installed in such a location that each dose
point is a equal distance from the supplying chamber or each supply hose is
of equal length (to prevent preferential dosing).

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Mechanical Installation
Install the SFoam Junior/Senior at ground level on a level site with good access to
the required services.
The SFoam Junior/Senior unit comes complete with Ø25 mm male screwed BSP
connections for the water and air lines and a Ø12 mm N.B. tube connection for the
chemical line.
It is recommended that the unit be situated as close as practicable to the chemical
storage tank, tote or drum. A flooded suction condition is preferred.
Each expansion chamber should be installed such that the foam delivery lines are
located at the top of the chamber and the solution and air inlets are located at the
bottom of the chamber. The expansion chambers should be located as close as
possible to the dose points.
Install a non-return valve to the air line on the inlet side of the expansion chamber.
When connecting the solution and air supply line to the expansion chambers, ensure
that the air line is connected to the Omega 510 flow meter and the solution line is
connected to the omega 505 flow meter. Note: It is recommended that each inlet
or delivery hose/pipe be a minimum of Ø20mm inside diameter with individual
foam delivery lines to be of lengths less that 15 meters.
Ensure that all pipe/hose lines are secured safely and tidily using weld-on double
pipe clamps or similar.
Connect the SFoam suction tube to the dosing feeder by unscrewing the securing
ferrule. For drums, fit the foot-valve to the end of the tube and place inside the drum.
For Bulki-Bins, a Camlock adapter must be attached to the container outlet and the
suction tube fits over the tail of the adaptor. For suction tube lengths greater than 2
metres, pre-fill the line with chemical to reduce delay at start-up. Note: The
maximum recommended suction tube length is 4 metres.
Select the desired solution concentration by turning the adjusting screw on the
dosing feeder and read the graduated scale. Note: DO NOT ADJUST SOLUTION
CONCENTRATION WHILE THE DOSING FEEDER IS OPERATING, THIS WILL
DAMAGE THE DOSING FEEDER.
Refer to appendix A for details regarding the typical setup of dose points utilising the
various brackets and nozzle types available.
Electrical installation
Note: All electrical installation work should be undertaken by an electrician or
other suitable qualified electrical person.
The SFoam unit will accept 90 to 260Vac single phase power. Refer to the electrical
schematic in Appendix E for further details.
A 24Vdc field switch such as a proximity probe, ultrasonic detector or photoelectric
cell can also be used to automatically start/stop the SFoam unit. Such a device
should be connected across terminals 2 and 6. A volt free N.O. contact may also be
used. Refer to Appendix E for further details.