FRC AUTOFOAM FSA015 User manual

FSA100 Rev1206
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FIRE RESEARCH CORPORATION
www.fireresearch.com
26 Southern Blvd., Nesconset, NY11767
TEL ( 631 ) 724-8888 FAX ( 631 ) 360-9727 TOLL FREE 1-800-645-0074
AUTOMATIC
AROUND-THE-PUMP
FOAM SYSTEM
MODELS: FSA015, FSA030, FSA060, FSA120
DocumentNumber:
XE-FSA0PM-R0A

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CONTENTS Table of Contents
CONTENTS ............................................................................................................... 2
INTRODUCTION...................................................................................................... 3
Overview ................................................................................................................ 3
Features.................................................................................................................. 4
Specifications......................................................................................................... 4
GENERAL DESCRIPTION....................................................................................... 6
Components .......................................................................................................... 6
Controls and Indicators ......................................................................................... 8
INSTALLATION ...................................................................................................... 10
Install Control Module ......................................................................................... 10
Install Metering ValveAssembly and Eductor ..................................................... 10
Install Flow Sensor(s).......................................................................................... 12
InstallSummingDevice........................................................................................ 18
Install Cables........................................................................................................ 18
Figure 8. Cables ....................................................................................................... 19
THEORY OF OPERATION .................................................................................... 20
OPERATION............................................................................................................ 22
Static Operational Check ..................................................................................... 22
Pump Intake and Discharge Pressure Requirements ........................................... 23
Operational Check ............................................................................................... 24
CALIBRATION........................................................................................................ 28
TROUBLESHOOTING TIPS ................................................................................. 30
MAINTENANCE ..................................................................................................... 31
Flushing the System ............................................................................................. 31
Cleaning the Paddlewheel Sensors....................................................................... 31
DRAWINGS ............................................................................................................. 32
List of Figures/Tables
Figure 1. Plumbing Schematic ................................................................................... 7
Figure 2. Controls and Indicators .............................................................................. 9
Figure 3. Control Module Dimensions..................................................................... 11
Figure 4. Metering ValveAssembly and Eductor Installation................................... 11
Figure 5. Flow Sensor Location Guidelines............................................................. 13
Figure 6. Saddle Clamp Installation ......................................................................... 15
Figure 7. Weldment Installation................................................................................ 17
Figure 8. Cables ....................................................................................................... 19
Table 1. Pump Pressure Requirements.................................................................. 23
Figure 9. Sample Displays ....................................................................................... 25
Figure 10. Summing Device ...................................................................................... 29
Figure 11. Eductor Drawing ...................................................................................... 32

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INTRODUCTION
Overview
The AutoFoam is an around-the-pump foam proportioning metering system. It
will automatically maintain a selected foam percent mixture regardless of water flow
fluctuations.The AutoFoam is microprocessorcontrolledandisautomaticinoperation.
The AutoFoam has easy to use controls and indicators. It becomes operational at
the push of a single button. Push buttons select the foam proportioning percent. An
uppermultifunctiondisplay shows the selected foam %, foam flow,andthetotal gallons
of foam used. A lower multifunction display shows the discharge flow rate and the
total gallons of water used. The operator can override automatic control by using the
manual override buttons to open or close the foam metering valve.
Around-the-pump proportioning systems operate with an eductor installed
between the water pump intake and pump discharge. A small flow of water from the
pump discharge passes through the eductor and creates a vacuum that draws foam
concentrate into the eductor.
The principle behind the AutoFoam system is straight forward. The flow rate on
the discharge side of the pump is measured.A metering valve is opened to allow foam
concentrate to flow and this flow rate is measured. The program compares the flow
rates and adjusts the metering valve to provide the correct amount of foam concentrate.
The foam concentrate is injected into the intake side of the pump by a venturi eductor
and mixed with water. This produces the correct foam proportioning percent at the
pump discharge. The AutoFoam constantly monitors foam and water flow and adjusts
the metering valve to ensure proper foam proportioning.
Features
CompleteAutomatic Foam Proportioning
Push Button Control
Flow Totaling for Both Foam and Water
Powers-Up at the Previous Proportioning Percent
ManualOverride
Multiple Discharge Sensors (Optional)

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Specifications
Power
SupplyVoltage: 12 VDC Nominal (24VDC SystemAvailable)
Supply Current: 1.5Amp Maximum
Foam Concentrate Induction
FSA120: 2 - 120 GPM
FSA060: 1.5 - 60 GPM
FSA030: 0.5 - 30 GPM
FSA015: 0.5 - 15 GPM
Maximum Discharge Flow Rate
AllSystems: 3000 GPM (Dependent on % Foam Solution)
Proportioning Ratio
FSA120: 1 - 10 %
FSA060: 0.5 - 6 %
FSA030: 0.5 - 6 %
FSA015: 0.5 - 6 %
Control Module
Power: 12VDC Nominal
Logic: 8-BIT Microcontroller
Housing: PaintedAluminum
Weight: 2 LBS
Environmental: Totally Sealed Enclosure with O-Rings
Connectors: Deutsch, Industrially Sealed
Discharge Flow Sensors
Type: Paddlewheel Type (Optional Moounts)
Sensor Material: Acetal (Delrin) with Stainless Steel (316) Shaft

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Metering Valve Assembly
Valve: Variable Orifice Linear Flow, With Position Sensing
Flow Sensors: Paddlewheel Type
Weight: 24 LBS
OverallLength: 16.25"
OverallHeight: 10"
Couplings
FSA120: 2.0"
FSA060: 1.5"
FSA030 1.5"
FSA015: 1.5"
Eductor
Material: Stainless Steel (304)
Weight: 4.2 LBS (FSA120)
Length
FSA120: 20"
FSA060: 12.5"
FSA030 12.5"
FSA015: 12.5"
Water Flow Rate Through Eductor @ 150 PSI
FSA120: 205 GPM
FSA060: 130 GPM
FSA030: 130 PM
FSA015: 50 GPM
Couplings: Victaulic (Grooved Type)
FSA120: Water Inlet 2.0", Foam Inlet 2.0", Discharge 2.0"
FSA060: Water Inlet 1.5", Foam Inlet 1.5", Discharge 1.5"
FSA030: Water Inlet 1.5", Foam Inlet 1.5", Discharge 1.5"
FSA015: Water Inlet 1.5", Foam Inlet 1.5", Discharge 1.5"

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GENERAL DESCRIPTION
Components
The AutoFoam system consist of the following components (Refer to Figure 1):
Control Module
MeteringValveAssembly
Eductor
Discharge Flow Sensor(s) and Sensor Housing(s)
SummingDevice
Cables
Control Module
The control module is panel mounted and has a front bezel measuring 4.25 by 4.25
inches. All controls and indicators are located on the front of the control module.
(Refer to Controls and Indicators.)
Metering Valve Assembly
The metering valve assembly includes a foam metering valve, two paddlewheel
type flow sensors, and mounting flanges. The metering valve has a position transducer
and it is internally calibrated for flow. The meter valve housing is brass. The flow
sensors are in stainless steel mounts.
Eductor
The eductor is located in a water by-pass loop and foam is sucked through it into
the suction side of the pump. It is made of stainless steel or brass.
Discharge Flow Sensor(s)
The discharge flow sensor is mounted on the pump discharge manifold. It provides
an input signal to the summing device that is proportional to the discharge flow. If the
multiple discharge flow sensor option is installed discharge flow sensors will be
mounted at each discharge.
Summing Device
Thesummingdeviceisconnectedbetweenthecontrolmoduleandtheflowsensors.
It contains the potentiometers used in flow calibration and provides flow datd to the
control module.
Cables
Interconnecting cables are provided. (Refer to Install Cables.)

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Figure 1. Plumbing Schematic
Foam Tank
EDUCTOR
Pump
Pump
Suction
Pump
Discharge
Power
12 VDC
Foam
Isolating
Valve
METERINGVALVE
with DUAL FOAM
FLOW SENSORS
FlushValve
Emergency Manual
Bypass Valve
DISCHARGE
FLOW SENSOR
CONTROL
MODULE
SUMMING
DEVICE
Check
Valve
Check
Valve

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Controls and Indicators
Allcontrolsandindicatorsarelocatedonthefrontofthecontrolmodule.Itcontains
the push button electronic controls and digital displays. (Refer to Figure 2.)
OFF Button
Press this button to turn the AutoFoam system off. The metering valve will go to
the closed position.
FOAM ON Button
Press this button to put the AutoFoam system in the automatic mode. It is used at
start up, to exit the manual override mode, or to show the selected foam percent in the
upper display.
Upper Display
An upper multifunction display shows foam concentrate flow, selected foam
percent, or the total gallons of foam concentrate used. The display will show OFF
when the system is off. When the system is turned on the selected foam percent is
displayed for three seconds then foam flow is displayed. When the FOAM % buttons
are pressed the display will show the selected foam percent for three seconds then go
back to show foam flow.
FOAM % Buttons
Press these buttons to raise or lower the percent of foam that is inducted. When
the increase or decrease button is pressed the upper display will show the selected
percent.
Lower Display
Alower multifunction display shows the discharge flow rate and the total gallons
of water used. If there is water flow on the discharge side of the pump, flow rate will
be displayed even if the AutoFoam system is off.
TOTAL Button
Press and hold the TOTAL button to display the total gallons of foam (upper
display x 1) and water (lower display x 100) that has been discharged.
Manual OVERRIDE Buttons
Press and hold the OPEN or CLOSE button for three seconds to set the system in
manual mode. The upper and lower displays will flash to indicate the system is in
manual mode and they will continue to show correct foam and water flow rates. In the
manual mode the operator is in control of opening or closing the foam metering valve
to set how much foam concentrate flows. To exit the manual mode the FOAM ON
button is pressed to start the automatic mode or the OFF button is pressed to turn the
system off.

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Figure 2. Controls and Indicators
Manual
OVERRIDE
Buttons
OFF
Button
FOAM
ON
Button Increase
Foam
Percent
Button
Decrease
Foam
Percent
Button
Upper
Display
Lower
Display
TOTAL
Button
FOAM
ON
OFF
FOAM
0PEN
CLOSE
OVERRIDE
TOTAL
P%
FOAM FLOW
WATER FLOW
%
M ANUAL

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INSTALLATION
Note: Plumbing systems are always unique and may cause small deviations
in the factory calibration. It is recommended that the calibration procedure
be performed after installation.
Install Control Module
1. Measure and mark mounting location for control module panel cutout and
mounting screw holes. Make sure there is clearance behind the panel before
cutting holes. Refer to Figure 3 for layout and dimensions.
2. Cut out a 3.75-inch diameter hole and drill four holes for 10-32 mounting
screws.
3. Place the control module in position and secure with four screws.
Install Metering Valve Assembly and Eductor
Four (4) piping connections must be made. (Refer to Figure 4.) Recommended
interconnecting pipe diameters for FSA120 are 2.0" and for FSA015/030/060 use 1.5".
Note: It is important that the metering valve assembly and the eductor be
mounted below the bottom of the foam tank.
Note: The metering valve assembly must be mounted so that the motor
assembly is on top.
1. Connect the pump discharge to the eductor inlet (A). Reinforced hose may
be used. If the water flow to the eductor needs to be shut off, a valve may be
placed in this line. This valve should have a 2.0" (1.5" for FSA015/030/060 )
throat and should be at least six (6) inches away from the eductor.
2. Connect the metering valve assembly outlet to the eductor foam inlet (B).
Piping must have groove couplings.
3. Connect the pump suction to the eductor discharge (C). Reinforced hose
may be used.
4. Connect the foam tank to the metering valve assembly foam inlet (D).
Reinforced hose may be used. (The metering valve assembly inlet is the side
where the two foam flow sensors are located). The piping into the metering
valve assembly inlet must have a straight run of at least eight (8) inches. A
check valve must be placed in this line at least one (1) foot away from the
metering valve assembly inlet.Aswing-check valve is preferred.

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Figure 3. Control Module Dimensions
Figure 4. Metering Valve Assembly and Eductor Installation
Interconnecting pipe diameters:
FSA120 system 2.0"
FSA015/030/060 system 1.5"
Valve motor assembly
must be on top.
MeteringValve
Assembly
Pump
Suction
From
Foam Tank Pump
Discharge
Eductor
Bypass and
Flush Valves
B
D
C
A
4.25"
3.5"
4.25"
3.5"
1" 4.5"
10-32
Hardware
3.75"

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Install Flow Sensor(s)
There are several ways to install FRC paddlewheel type flow sensors. Mounting
options include saddle clamps, weldments, pipe tees, and special adapters. Each mount
will meet particular plumbing requirements.
The maximum pressure for a flow sensor installation is 600 PSI.
Note: Plumbing systems are always unique and may cause small deviations
in the factory calibration. It is recommended that the calibration procedure
be performed after installatoin .
Flow Sensor Location
The location of the flow sensor in the plumbing system is critical. The flow of
water at and around the sensor must be laminar, or smooth, to ensure accurate flow
measurements. There must be enough straight pipe run before the flow sensor location
to allow the water stream to stabilize into a uniform flow. Guidelines for selecting
flow sensor locations are outlined in Figure 5.
When the sensor is mounted after an area in the plumbing that tends to increase
water stream turbulence (a valve, increase in pipe diameter, etc.), it is critical that
steps are taken to stabilize the flow.
•When a pipe is reduced in diameter the water stream tends to be squeezed
into a more uniform flow. This can be used to help stabilize flow when
there is not a sufficient pipe run up stream.
•FRC offers an optional flow conditioner that replaces the standard sensor
housing. It protrudes into the water stream at the sensor location and is
specially shaped to reduce local turbulence.

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The preferred location for the mounting
of a flow sensor is on the top half of the
pipe. The best orientation is vertical. If
the sensor is mounted on the bottom of
the pipe, it may be susceptible to the
accumulation of dirt.
When mounting the sensor after an elbow
the length L must be at least 6 times the
pipe diameter.
When mounting the sensor before a valve
or an elbow the length L must be at least
equal to the pipe diameter.
When mounting the sensor after the pipe
diameter is reduced the length L must be
at least 2 times the pipe diameter.
When mounting the sensor after a valve
the length L must be at least 14 times the
pipe diameter.
Figure 5. Flow Sensor Location Guidelines
Best Orientation
L
L
L
L
After Elbow
L > 6 X PIPE DIA.
Before Valve or Elbow
L > 1 X PIPE DIA.
After Reduction
L > 2 X PIPE DIA.
After Valve
L > 14 X PIPE DIA.

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Saddle Clamp Installation
Note: Ensure that the mounting location meets the requirements for uniform
water flow. (Refer to Flow Sensor Location.)
Note: Ensure that there is enough room for the saddle clamp, sensor, and
connector to fit. (Refer to Figure 6.)
1. Drill and deburr a 1-11/16" to 1-3/4" diameter hole at mounting location.
2. Clean pipe surface in area where saddle clamp gasket will seal.
Note: The sensor housing is epoxied in the saddle clamp with the alignment
tab in the correct position and is not meant to be removed.
3. Place saddle clamp over hole with sensor housing centered.
4. Tighten saddle clamp nuts until gasket makes a good tight seal.
5. Insert flow sensor into sensor housing. Align flat spot on sensor rim with
alignment tab and make sure o-ring is in the groove.
Note: The retainer cap only needs to be hand tightened. There is an inside
lip that will stop the cap from turning when it makes contact with the
alignment tab. This provides the correct pressure to make the seal at the
o-ring. Make sure the flow sensor does not disengage from the alignment
tab and rotate.
6. Install retainer cap and hand tighten.
7. Connect flow sensor cable. (Refer to Install Cables.)

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Figure 6. Saddle Clamp Installation
Note: These dimensions are typical
and are given to be used as an aid
in determining mounting locations
for flow sensors.
Note: Allow a minimum of 2
inches clearence at the sensor
top for removal/installation of
the connector.
Note: When the retainer cap is
tightened make sure the sensor
rim flat spot does not disengage
from the alignment tab and
allow the flow sensor to rotate.
Pipe Size Dimensions
(Sch 40) A B C
2 5.5 3.9 2.9
2.5 5.5 3.9 2.8
3 5.9 3.9 2.8
3.5 6.8 4.3 2.8
4 6.8 4.3 2.8
5 8 4.3 2.8
Measurements are in inches.
Sensor
Housing
Paddlewheel
Flow Sensor
Retainer Cap
Saddle
Clamp
Alignment
Tab
O-Ring
A
C
B

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Weldment Installation
Note: Ensure that the mounting location meets the requirements for uniform
water flow. (Refer to Flow Sensor Location.)
Note: Ensure that there is enough room for the weldment, sensor, and
connector to fit. (Refer to Figure 7.)
1. Drill and deburr a 1-11/16" to 1-3/4" diameter hole at mounting location.
2. Center weldment mount over hole and weld it to pipe. The weld must be
continuous around the fitting with no gaps or voids.
3. Screw sensor housing into weldment. Run it down far enough to make sure it
will go through the pipe freely then back it out.
Note:The paddlewheel sensor must be correctly aligned in the water stream.
The alignment tab is used to set the position of the sensor. Make sure that
the alignment tab is centered on the pipe centerline. (Refer to Figure 7.)
4. Set sensor housing to dimensionAin Figure 7. Make sure the alignment tab is
centered on the pipe as shown (it can be on upstream or downstream side).
5. Screw on tru-seal locknut and tighten with a 2" wrench using light to medium
torque. Make sure that housing does not rotate causing dimensionAto change
and the sensor housing alignment tab remains centered.
6. Insert flow sensor into sensor housing. Align flat spot on sensor rim with the
alignment tab and make sure o-ring is in groove.
Note: The retainer cap only needs to be hand tightened. There is an inside
lip that will stop the cap from turning when it makes contact with the
alignment tab. This provides the correct pressure to make the seal at the
o-ring. Make sure the flow sensor does not disengage from the alignment
tab and rotate.
7. Install retainer cap and hand tighten.
8. Connect flow sensor cable. (Refer to Install Cables.)

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Figure 7. Weldment Installation
Note: Allow a minimum of 2 inches
clearence at the sensor top for removal/
installation of the connector.
Pipe Size Dimension
(Sch 40) A
1.5 1.95 to 1.80
2 1.95 to 1.80
2.5 1.90 to 1.75
3 1.88 to 1.73
3.5 1.88 to 1.73
4 1.85 to 1.70
Measurements are in inches.
Note: These dimensions are
typical and are given to be
used as an aid in determining
mounting locations for flow
sensors.
Make sure that the alignment tab is
centered on the pipe centerline.
Note: When the retainer cap is
tightened make sure the sensor
rim flat spot does not disengage
from the alignment tab and
allow the flow sensor to rotate.
Retainer Cap
Paddlewheel
Flow Sensor
Tru-Seal
Locknut
Sensor
Housing
Weldment
Alignment
Tab
O-Ring
Alignment
Tab
A
Pipe
Centerline
2.8"
2.5"

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Install Summing Device
The summing device mounts with two screws. Make sure there is room to connect
the cables and adjust the potentiometers.
Install Cables
Cables need to be connected from the control module to power, to the metering
valve, and to the summing device. The standardAutoFoam has three cables connected
from the summing device to the flow sensors. (Refer to Figure 8.)
1. Connect the control module power cable. A 5' power extension cable is
provided. Connect the extension cable red wire to the truck 12/24 VDC
(positive). Connect the black wire to ground.
2. Connect two (2) foam flow sensors to the summing device with the extension
cables supplied .
3. Connect the discharge flow sensor to the summing device with the extension
cable supplied.
For the multiple discharge flow sensor option, connect all discharge flow
sensors to the discharge flow summing device. The output of the discharge
flow summing device is then connected to theAutoFoam summing device. (If
a flow display is needed, a Y-cable can be used to connect the flow sensor to
both the summing device and a flow display.)
4. Connect the summing device to the control module.
5. Connect the metering valve to the control module.
Perform the Static Operational Check at this time to verify manual operation of
the metering valve. (Refer to Operation section.)

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Figure 8. Cables
○○○
Red Wire
12/24
VDC
Black Wire
GND
Power
Metering Valve and
Dual Flow Sensors
AUTOFOAM
Summing Box
Metering Valve
Multiple Discharge
Flow Sensor Option Discharge Flow
Sensor
○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○
Y-Cable
AutoFoam
SummingDevice
Discharge Flow
Summing Device
Discharge Flow
Sensor
Flow
Display
○○○○○○○○○○○○○○○
○○
○○○○○○○○○○
○○○○○○○○○○
○○○○○○○○○○

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THEORY OF OPERATION
The operation of the AutoFoam system is controlled by a microprocessor housed
in the control module. The programming enables the AutoFoam system to operate in
three different modes.
Automatic Mode
This is the normal mode of operation. In this mode of operation the flow rate of
foam concentrate is determined by the percent selected on the control module and
inputs from the flow sensors. The microprocessor controls the opening or closing of
the metering valve to provide the correct foam solution at the pump discharge.
When in the automatic mode the flow sensors provide constant feedback of flow
rate information. Dual flow sensors mounted on the metering valve assembly monitor
foam concentrate flow rate. The discharge flow sensor measures the solution (foam
concentrate and water mixture) flow rate at the discharge side of the pump. This flow
rateinformationallowsthe system tomaintaintheselectedfoam proportioningregardless
of discharge fluctuations.
The metering valve controls the amount of foam concentrate that flows into the
eductor. The eductor injects the foam concentrate into the suction side of the pump.
The flow rates of the foam concentrate and the foam solution is processed. The flow
rates are displayed and the metering valve is adjusted to produce the selected foam
proportion.
If input data from one of the dual foam concentrate flow sensors is lost the program
will automatically use the information from the one that is operating properly. There is
no loss in performance or accuracy of the system. If input data from both foam flow
sensors is lost, the AutoFoam system will switch over to the fixed program mode.
Fixed Program Mode
The system will enter this mode when there is no input data from both foam
concentrate flow sensors. In this mode of operation the flow rate of foam concentrate
is determined by information stored in theAutoFoam program. When the system is in
this mode an F will be shown in the upper display. TheAutoFoam system will exit the
fixed program mode automatically when input data from a foam concentrate flow
sensor is detected.
The foam concentrate flow rate is determined by the percent selected on the control
module and water flow at the discharge. It is an important factor in determining if there
isafailureintheAutoFoamsystemwhenthereisno input datafromthefoamconcentrate
flow sensors.
When in the fixed program mode stored precalibrated valve position data is used
to adjust the metering valve. There is a transducer in the valve assembly that provides
feedback on the valve position. The valve position is directly related to how much
foam concentrate flows. The program uses the selected foam proportion percent and
the discharge water flow rate to position the valve for the correct foam concentrate rate
of flow.