FOAMICO B 540-27 F User manual

1B 540-27-F + feed pump_7009077 US –07-02-2019
Manual
FOAMICO Booster Station
B 540-27 F + Feed pump (7009077)

2B 540-27-F + feed pump_7009077 US –07-02-2019
Content
1Introduction 3
1.1 Condition of liability 3
1.2 Guarantee conditions. 3
1.3 Protection against frost 4
1.4 Safekeeping 4
1.5 Declaration of conformity 4
1.6 General information regarding the operator´s manual 4
2Safety 5
2.1 Safety during operation of the system 5
2.2 Precautionary measures 8
2.3 Appropriate utilization 8
2.4 Transport 9
3Installation 9
3.1 Safety instructions for Mounting and Installation 9
3.2 Location and Mounting 10
3.3 Water Supply 10
3.4 Electrical Supply 11
4Operation 12
4.1 Start procedure 12
4.2 Stop procedure 13
5Troubleshooting 15
5.1 Failures control system 15
5.2 The pump does not start 16
5.3 The pump wont stop 16
5.4 Red light illuminated at the pump 16
5.5 Other faults. 17
6Maintenance 18
6.1 Rinsing hose. 18
6.2 Nozzles. 18
6.3 Low pressure valves / guns 18
6.4 Couplings. 18
6.5 Ball valves. 19
6.6 Non-return valves 19
6.7 Suction filter / chemical hose. 19
7Technical Data 20
7.1 Resulting outlet pressure. 20
8Spare parts 21
8.1 Booster B 540-27 F –Feed pump 21
9Wiring diagram 23
9.1 Flow Diagram 24
10 Name Plate 25
11 Declaration of Conformity 26

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1 Introduction
FOAMICO congratulates you with your new Booster system. The B 540-27 is developed to connect to
FOAMICO Cleaning Satellites. The Booster series are developed to be used for professional cleaning
purpose. The system is manufactured mainly of high grad stainless steel. It is designed to meet today’s high
hygiene standards.
NOTICE
To use and operate the system this manual must be read carefully.
Attention! To use and operate the system this manual must be read carefully.
1.1 Condition of liability
The responsibility for the treatment and operation in an appropriate manner rests with each individual user.
Thus it is of great importance that this manual is available to the sanitary employee at any time.
1.2 Guarantee conditions.
For a period of 12 months from the date of delivery your dealer warrants for parts which don’t function due
to defects of material or production. This guarantee does not cover wearing parts (as described in the section
about spare parts). This guarantee is covering the replacement or repair of the defect part. Any dismounting,
forwarding, and mounting expenses are paid by the purchaser. The costs for any possible return from
FOAMICO after finished repairs rest with FOAMICO. The defect parts are the property of FOAMICO
Claims which might be raised for any other legal reason, or normal wear and tear, as well as damage on parts
which can be related to negligent or wrong treatment, are not covered by this guarantee.
This guarantee does not cover at all, if the system has been exposed to frost.
This guarantee becomes void if changes or repairs have been implemented by non-authorized persons. Any
claims under the guarantee will only be accepted if they are announced to
FOAMICO immediately after the damage has been observed. This guarantee becomes void as soon as the
system changes ownership.
Dealers and FOAMICO cannot be held responsible for personal injuries, damages to equipment, loss of
earning including those caused by production loss, loss of stock or the like, which might arise from
inappropriate or delayed delivery of the sold product, regardless the reason, including defects in production
or material. In addition, please read our usual terms of sale and delivery
WARNING
Due to the nature of low pressure cleaning systems Pressure surges can occur. The installer is responsible for
dimensioning the supply line to be able to adapt Pressure surge.
Dealers and FOAMICO cannot be held responsible for personal injuries, damages to equipment surrounding
rooms, Water Supply line or water outlet line.

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1.3 Protection against frost
The equipment should only be installed in frost free rooms.
Prior to being exposed to frost, the system must be emptied for water (frost protected). Even shorter periods
of exposure to frost can damage the equipment.
VORSICHT!
This symbol refers to safety and danger moments. Neglect of these instructions can cause damage on persons
and objects.
1.4 Safekeeping
You are requested to store this manual in a place where it is at your disposal at any time, and it should be
handed over to the person responsible for this product. Should the manual get lost, please don’t hesitate to
require another one from your agent
1.5 Declaration of conformity
We FOAMICO declare that this product is in conformity with the following directives:
- Machinery (2006/42/EC).
- Electromagnetic compatibility (2004/108/EC).
- Electrical equipment designed for use within certain voltage limits ( 2006/95/EC)
- Electrical equipment designed for use within certain voltage limits ( 2006/95/EC): standard used: EN
61800-3:2004
1.6 General information regarding the operator´s manual
DANGER
The threat of immediate danger exists
Possible consequences: Death or severe injury.
Prevention
WARNING
A potentially dangerous situation
Possible consequences: Death or severe injury.
Prevention

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CAUTION
A dangerous situation
Possible consequences: light or minor injuries. Can also be used in warn
against damage to porperty or other goods.
Prevention
NOTICE
A potentially damaging situation
Possible consequences: the product or something in its vicinity could be
damaged.
Prevention
2 Safety
2.1 Safety during operation of the system
WARNING
Burn hazard
The operating machine presents a danger of scalding from hot water at
70°C.
Suitable working clothes are recommended, e.g. goggles, respirators, and rubber
gloves should always be used.
WARNING
Danger of slipping
Because due to water and foam the floor sometimes can get slippery.
The use of non-slip footwear is recommended.

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WARNING
Risk of poisoning / risk of allergic reactions
Improper use of detergents can be dangerous, it can produce poisonous gas,
severe chemical burns an allergic reactions.
Do not connect or use detergent before having read the instructions from the
Detergent supplier. Always consult the Detergent supplier to get instructions for
correct use.
NOTICE
The system should not be started up before the operator using the system,
has been instructed in the correct utilization, adjustment, and maintenance
of it.
WARNING
Risk of eye injuries, ear damage, danger of swallowing, loss of
stability
Directing a jet of water, cleaning fluid or liquid disinfectant at persons can
lead to eye injury or ear damage, swallowing or the loss of stability.
Never direct the water jet towards persons.
CAUTION
Risk of injury
Risk of injury by the sudden escape of pressurised fluid (cleaning fluid and
disinfectant).
Make sure that the couplings ”lock“ when the hose and nozzles are connected.
Always follow this procedure before use.
Always depressurize the system after use. This is done by first closing the valve for the water supply and
afterwards opening the low-pressure valve or gun.
During operation of the system: ensure that the low-pressure gun/valve is closed, before releasing the
coupling and change the nozzle.

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CAUTION
Risk of injury
When the low-pressure gun/nozzle is opened, the water jet will cause a
certain back pressure.
Make sure to have a strong grip on the handle and a firm foothold.
WARNING
Risk of ear damage
The noise level from the equipment is less than 70dB (A). During rinsing,
the operator is exposed to a higher noise level and can lead to loss of
hearing. This is caused by the impact from the water jet on the
surroundings.
It is therefore recommended the use ear protectors during the cleaning process
NOTICE
The hand-arm vibration level, measured by using a low-pressure gun
mounted with a rotating nozzle, is below 2.5 m/s² (8.2ft/sec2).
DANGER
Electrocution hazard
A jet of water directed towards electric equipment can lead to injury from
electrocution or damage the equipment.
Never direct the water jet towards electrical equipment.
WARNING
Electric shock
Water on electric connections can lead to injury from electrocution or
damage the electric equipment.
Avoid water near electric plugs.

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DANGER
Electrocution hazard
Unprofessional work on the electric equipment can result in severe injury
and death.
Switch of the power supply, before connecting or removing a plug from electric
outlets.
NOTICE
Use only original FOAMICO Nozzles, hoses, couplings and spare parts.
2.2 Precautionary measures
The construction of the system is in accordance with the generally adopted, technical requirements and the
stipulations concerning working environment and accident prevention. Therefore the equipment must be in
its best technical state before being used, and must only be utilized according to its requirements and by
observance of the precautionary measures and operational instructions. Disturbances, which might influence
the safety, must be rectified immediately.
2.3 Appropriate utilization
FOAMICO low-pressure system is manufactured with the purpose of:
Rinsing with water, spreading foam and sanitizer within the stated boundaries.
Any other kind of application or use beyond this is considered to be inappropriate and deviant concerning the
requirements, and may lead to dangerous situations. FOAMICO is not liable for any sequential damages
brought about by this.
Appropriate utilization includes the following:
The instructions, regulations, and recommendations given in this manual.
The observance of the prescribed intervals for inspection and maintenance.
The correct maintenance for good operational condition of the system.
The observance of the prescribed conditions for the environment and operation
DANGER
Risk of chemical burns
Improper handling of chemicals results in a risk of chemical burns.
When handling chemicals, ensure that the information provided by the chemical
supplier is strictly observed.
The foam is adjusted by means of maximum nozzles, be sure to observe recommendations of the respective
chemical supplier.

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2.4 Transport
WARNING
Property damage
Improper transport of the unit presents a danger of personal damage and
damage to machines.
The equipment shall only be moved with suitable hoists.
Before any transport of an apparatus, which has already been in operation, you are advised to remove
residual detergent from the pipes. Insert the suction probe in a container with clear water. By starting the
cleaning process several times you thoroughly rinse the pipes with fresh water.
Regarding the disposal of the unused detergent, observe the manufacturer’s instructions.
3 Installation
3.1 Safety instructions for Mounting and Installation
CAUTION
Personal injury and damage to property may result from the
installation of damaged parts
The installation of damaged parts may cause personal injury and damage to
property.
Never install or apply damaged products. Claims concerning damages must be
made to the carrier immediately.
CAUTION
Danger of damage to property and personal injury
In cases of irregular installations there is a risk for major damages on both
material and people.
Work in the connection with installations, start up, and maintenance on the
Foamico cleaning systems should only be done by authorized electricians,
because the valid national regulations concerning prevention of working
accidents. E.g. high voltage regulations: EN 60204-1 (IEC 204-1), VBG4 DIN-
VDE 0100/0113/0160 or other local regulations) must be respected.

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3.2 Location and Mounting
WARNING
Danger of damage to property and personal injury
Improper installation of the unit presents a danger of personal damage and
damage to machines.
The equipment shall only be moved to the final installation place, with suitable
hoists..
The system should always be located in a frost-free room. Stationary system must always be mounted where
the surfaces are of solid quality, and when applicable the fastening must always be done with the delivered
bolts and raw plugs. Holes for wall brackets must be drilled according the dimensional drawing.
The booster should be connected to an adequate pipe system. This should correspond to distance from the
water supply, the maximum water flow and vertical distance from the boosting System.
3.3 Water Supply
NOTICE
Connection to water supply should always be done in according to local or
national standards.
If the legislation in your country requests safeguards for reverse current,
this must be provide for.
BEFORE mounting the system, the piping must be flushed with water in order to remove possible parts or
dirt.
CAUTION
Damage to equipment caused by blockage
Any wastewater entering the machine may severely damage the equipment.
At the supply pipe to the main station a valve and filter must be installed. We
recommend using Original FOAMICO installations set.
CAUTION
Damage to equipment caused by blockage
Any wastewater entering the machine may severely damage the equipment.
Before the satellite a valve and filter must be installed. We recommend using
Original FOAMICO installations set.

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The water should be connected to the inlet shown in POS A. fig. 4.1
CAUTION
Property damage
If the pump runs dry it may be damaged.
The pump must be filled with water and vented. Open the vent valve POS. D
fig. 4.1, until all air is out of the pump.
After venting the Feed pump, the green push button (pre-boost) can be used
to pressurize the two Booster pumps.
AFTER mounting the system flushing of the pipes must always be done with the system in “rinsing mode”,
in order to avoid any impurities in the injector system. Please keep rinsing until the rinsing nozzle shows an
invariable clean water jet coming out.
3.4 Electrical Supply
DANGER
Elektric shock, electrocution
Unprofessional work on the electric equipment of the main station can
result in severe injury and death.
The user or the installer is responsible for the installation of correct earthing and
protection according to current national and local standards. All operations must
be carried out by qualified personnel.
Connection to the power supply must only been made by authorised
electrician’s´. The connection has to be done to a main switch installed next to
the station. Always consult the pump manual before making the connections.
DANGER
Elektric shock, electrocution
Any work being carried out on the electric parts of the pump without it
having been disconnected from the electrical supply can lead to severe
injury and death.
Never make any connections in the pump terminal box unless electric supply
circuits have been switched off for at least 5 minutes.
CAUTION
Connection the power supply must only been made by authorised
electrician’s´.

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CAUTION
The connection has to be done to a main switch installed next to the station.
Always consult the pump manual before making the connections
Supply voltage and mains: 3 x 380-480 V. -10%/ + 10 %, 50/60 Hz, PE.
NOTICE
The voltage and frequency is marked on the main station’s and the pumps
nameplates. Make sure they are suitable for the electricity supply of the
installation site.
4 Operation
4.1 Start procedure
CAUTION
Equipment damage caused by dry running
If the system runs dry or partly filled the pump and other components may
be damaged.
Do not start the main station until the pipe system has been filled with water and
vented. Do not start the main station until the pump has been filled with water
and vented. Vent the pump through the venting valve POS I. Fig. 5.1
START:
CAUTION
Damage to the environment from water escaping
The water escaping from the equipment may damage the environment.
Make sure that all outlets are closed before starting the main station.
2. Turn the switch POS C fig. 4.1 into “I”. The system is now ready. The pump will start automatically when
a Satellite or water outlet is operated. When there is now activity the pump will stop automatically and be in
standby as long at the switch is in position “I”.

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4.2 Stop procedure
1. The booster is stopped by turning the switch POS C fig. 4.1 into “0”.
NOTICE
When the system is not used it is recommended to Turn the switch POS C
fig. 4.1 into “0”
3.
NOTICE
In case of service the Electrical main switch shall always be turn off.
STOP:
Turn the On/Off switch POS. C, Fig. 4.1, into position “Off”. The booster station is now stopped.
Read the section on “Operating mode“ in the Grundfos manual “Grundfos Hydro Multi”.
ATTENTION! In case of service the main switch POS F, fig 4.1 shall always be turned off, into position “0”
Figure 4.1
A. Connection for water supply
D. Bleeding valve pump
B. Connection to Booster station outlet
E. Advanced control panel
C. Switch for start/ stop.
F. Main Switch

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Figure 4.2 Display photo pump stopped
•Operating mode: Stop. Pump is stopped
•Resulting setpoint. Setpoint = inlet pressure + maximum pump pressure. (maximum setpoint 27 bar)
•Inlet pressure: Actual measured inlet pressure.
•Liquid temp.: water temperature in top of the pump.
Figure 4.3 Display photo Pump running
•Discharge press: Stop. Actual discharge pressure from pump. (maximum setpoint 27 bar)
•Resulting setpoint. Setpoint = inlet pressure + maximum pump pressure. (maximum setpoint 27 bar)
•Inlet pressure: Actual measured inlet pressure.
•Liquid temp.: water temperature in top of the pump.

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5 Troubleshooting
ATTENTION! When the system is service, the main power switch POS. F Fig. 4.1 must be turned off!
Fault
Cause
Action
No rinsing pressure.
Booster or main station not started.
Start booster/or main station.
Too many users on the same time.
Check maximum number of users.
The ball valve at the outlet of the system
is not opened.
Open the ball valve
The water level in the tank is below
minimum
Fill the tank
The ball valve at the inlet of the system is
not opened.
Open the ball valve.
Unstable rinsing pressure.
Unoriginal rinsing nozzle with too high
water consumption is used.
Change to master rinsing nozzle –observe
technical data for model.
5.1 Failures control system
ATTENTION! When the system is serviced, the main power switch must always be switched off.
Consult the Grundfos manuals
Read the failure At the Operating panels and consult the Grundfos manual “Hydro Multi-E” for reset the
failure.
Is the pump still not running call a service technician.

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5.2 The pump does not start
The pump does not start even though there is flow through the pump. Do the following:
Reset the unit. Turn the Switch POS. C fig 4.1 into “0” position for 5 seconds. Turn the Switch POS. C fig
4.1 into rinse position “I”. If this does not help and the green light at the pump is not illuminated check the
power supply. If the green light at the pump is illuminated and the pump is not running investigate the flow
switch. Is the pump still not running call a service technician.
5.3 The pump won’t stop
The pump does not stop. Investigate the following:
Check for water leakages in the pipe system
Check the non-return valve
Check the flow switch
Reset the unit. Turn the Switch POS. C fig 4.1 into “0” position for 5 seconds. Turn the Switch POS. C fig
4.1 into rinse position “I”. If the problem is still not solved, contact service technician.
5.4 Red light illuminated at the pump
The pump does not start or has suddenly stopped and the red light is illuminated, then investigates the
following:
-Dry run –Ext. fault: Is the water level in the tank above min.?
External fault (3): The water level in the tank is below minimum.
Check the water level in the tank.
Reset the unit. Turn the Switch POS. C fig 4.1 into “0” position for 5 seconds. The unit will start when there
is water consumption
Follow the instruction at the display to set it back to the home screen, fig. 4.2

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- High water temperature Limit 2 exceeded: is the supply water below 70°C/158°F??
Limit 2 exceed: The water temperature at the top of the pump has been higher than 80°C/176°F for more
than 3 seconds.
Check the temperature setting for the water supply. Maximum water temperature is 70°C/158°F?.
-ATTENTION: Before it is possible to reset the system it must cool down to below 80°C/176°F. This may
take 15-25 minutes
Reset the unit. Turn the Switch POS. C fig 4.1 into “0” position for 5 seconds. The unit will start when there
is water consumption
Follow the instruction at the display to set it back to the home screen, fig. 4.2
High motor temperature –pump has been overloaded –reduce load.*
If the failure has been one of the above and the problem has been solved. Reset the unit. Turn the Switch
POS. C fig 4.1 into “0” position for 5 seconds. The unit will start when there is water consumption.
5.5 Other faults.
Read the display and consult the Grundfos manual which were delivered together with the equipment.
If this do not solve the problem Contact a service technician.

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6 Maintenance
ATTENTION! When the system is serviced, the main power switch must always be switched off.
6.1 Rinsing hose.
WARNING
Risk of chemical burns
Damaged hoses can lead to injury from chemical burns.
The rinsing hose should be checked for any damage or week point before taking
it into use every day.
Do not drive across the hose. Be careful not to damage the hose on any sharp
edged or corners.
WARNING
Danger of poisoning
A damaged hose can cause injury from poisoning or harmful vapours.
The rinsing hose should be checked for any damage or week point before taking
it into use every day.
Do not drive across the hose. Be careful not to damage the hose on any sharp
edged or corners.
For security reasons it is recommended to change the hose at least once every 12 months.
6.2 Nozzles.
Nozzles are warned over time. And warned out nozzle is less effective. It can result in less rinsing power,
higher water usage, higher chemical consumption. Check the nozzles on a regular basis. 1 to 2 times every
month is recommended. Change the nozzle if they are damaged. To be sure you will get the optimized result
we recommend using FOAMICO nozzles.
6.3 Low pressure valves / guns
They must be checked regular. The nut on the handle has to tighten regularly. Check couplings, swivels,
handles for any damaged. A damaged part must be changed for security reasons.
6.4 Couplings.
Couplings should be cleaned and greased on a regularly basis. Use only approved grease. This will extend
the live time of couplings. Always make sure there is a nozzle or lance mounted in the coupling before
opening. Rinsing through an open coupling can damage the O-rings.

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6.5 Ball valves.
Every ball valve on the inlet for water inlet for air outlet for water/foam and outlet for sanitizer must be
adjusted.
First time, after one week, and then, once every month. Tight the nut on the handle to avoid leakage.
6.6 Non-return valves
NOTICE
Non-return valves are very important to secure a correct function of the
system.
Non return valves for air: The system has 2 non- return valves for air. The purpose of these is to prevent
water running back into the air system. Due to the potential risk, the air system for the cleaning system must
be separate from other air systems.
NOTICE
Never leave the valve for air open. Always secure it is closed when not
foaming!
CAUTION
Property damage to on-site pneumatic equipment
The cleaning system shall always have its own air supply system. Failure in
the cleaning system could accidentally lead to water and/or detergent can
flow back in the air system. To avoid damage on other installations.
It is mandatory to make a separate air supply system for the cleaning equipment.
Never leave the valve for air open. Always secure it is closed when not foaming!
If leakage of water is observed anywhere in the airline, both non-return valves must be changed.
- Non-return valve for chemical: The system has one for each chemical intake. The purpose is to prevent
water running back into to chemicals. It will dilute the chemical and result in none or bad foam quality and to
low concentration
NOTICE
Non- return valves should be checked once every week. It is recommended to
change every 1-2 year. Use only Original FOAMICO non-return valves.
Use only Original Foamico non-return valves.
6.7 Suction filter / chemical hose.
The suction filter for chemical should be clean once every week. It is recommended to change filter and
chemical inlet hose every year.

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7 Technical Data
Water: Unit B 540-27 F –Feed pump
Max. water consumption l/min. 540
Max. Temperature °C 70
Pipe dimension inlet inch 3”
Pipe dimension outlet inch 3”
Power Supply:
Standard voltage V 380-500
Hz 50/60
Max power consumption kW 27
Nominal current A 54,8 A –43,3A
Fuse A 63
Dimension (W x H x D) mm 1645 x 1070 x 905
Weight kg 450
*** All Measurements are average
7.1 Resulting outlet pressure.
The pump is programmed to deliver the maximum possible outlet pressure. It automatically regulates it
according to the inlet pressure and the actually load (number of simultaneous users at the same time.
This table shows the average possible outlet pressure. Maximum setpoint is 27 bar.
Inlet pressure
Bar
2,0
3,0
4,0
5,0
6.0
7,0
Resulting
setpoint
Bar
22,0
23,0
24,0
25,0
26,0
27,0