Godiva Hale SmartFOAM 1.7AHP User manual

SmartFOAM
Electronic Foam Proportioning Systems
Models:
Class A only – 1.7AHP, 2.1A
Class A/B – 3.3, 5.0, 6.5
FOAM SETUP
GUIDE
FSG-MNL-00177
HALE PRODUCTS, INC / CLASS 1
607 NW 27th Avenue ●Ocala, FL 34475
U.S.A.
Telephone: [phone]
FAX: [phone]
GODIVA LTD.
Charles Street ●Warwick, England CV34 5LR
Phone: [phone]

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SmartFOAM
APPARATUS INFORMATION
Hale SmartFOAM System Serial Number
In Service Date
Fire Department
Engine Number
Calibration Factors:
Water Flow – high calibration point
Water flow
Pulses
Water Flow – low calibration point
Water flow
Pulses
ClassAFoam Factor
NOTICE!
Hale Products does not assume responsibility for product failure resulting from improper maintenance or operation.
Hale Products is responsible only to the limits stated in the product warranty. Product specifications contained in this
manual are subject to change without notice.
All Hale products are quality components -- ruggedly designed, accurately machined, precision inspected, carefully
assembled and thoroughly tested. In order to maintain the high quality of your unit, and to keep it in a ready condition, it
is important to follow the instructions on care and operation. Proper use and good preventive maintenance will lengthen
the life of your unit.
REVISION RECORD
REV
Date
Page
Description
A
APR2018
All
New Issue

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SmartFOAM
NOTES

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SmartFOAM
SAFETY
IMPORTANT!
THE HALE SMARTFOAM MODELS 2.1A AND
1.7AHP CLASS “A” ELECTRONIC FOAM
PROPORTIONING SYSTEMS ARE DESIGNED FOR
OPTIMUM SAFETY OF ITS OPERATORS
AND TO
PROVIDE RELIABLE AND SAFE FOAM
CONCENTRATE INJECTION. FOR ADDED
PROTECTION AND BEFORE ATTEMPTING
INSTALLATION OR OPERATION PLEASE FOLLOW
THE SAFETY GUIDELINES LISTED IN THIS
SECTION
AND ADHERE TO ALL WARNING,
DANGER, CAUTION AND IMPORTANT NOTES
FOUND WITHIN THIS
GUIDE.
THIS SECTION ON SAFETY MUST BE CAREFULLY
READ, UNDERSTOOD AND ADHERED TO
STRICTLY
BY ALL INSTALLERS AND OPERATORS
BEFORE
ATTEMPTING TO INSTALL OR OPERATE
THE SMARTFOAM PROPORTIONINGSYSTEM.
INCORPORATE THE WARNINGS AND CAUTIONS
AS WRITTEN WHEN DEVELOPING
DEPARTMENTAL APPARATUS OPERATING
PROCEDURES.
SmartFOAM is a trademark of Hale Products,
Incorporated. All other brand and product names
are the trademarks of their respective holders.
GUIDELINES
READ ALL INSTRUCTIONS THOROUGHLY BEFORE
BEGINNING ANY INSTALLATION OR OPERATION
PROCESS.
❑Installation should be performed by a trained and
qualified installer, or your authorized Hale
Products service representative.
❑Be sure the installer has sufficient knowledge,
experience and the proper tools before attempting
any installation.
❑Make sure proper personal protective equipment is
used when operating or servicing apparatus.
❑Afoam tank low level sensor must be utilized to
protect the Hale Foam proportioner from dry
running. Failure to use a low level sensor with the
Hale Foam system voids warranty.
❑DO NOT permanently remove or alter any
guard or insulating devices, or attempt to
operate the system when these guards are
removed.
❑Make sure all access/service panels and covers
are installed, closed and latched tight,
where
applicable.
❑DO NOT remove or alter any hydraulic or
pneumatic connections, electrical devices, etc.
DO NOT tamper with or disconnect safety
features or modify protective guards (such as
covers or doors). DO NOT add or remove
structural parts. Doing so voids the warranty.
Any of the above could affect system capacity and/or
safe operation of the system and is a serious safety
violation which could cause personal injury, could
weaken the construction of the system or could affect
safe operation of
the SmartFOAM Proportioning
System.
WARNING!
NO MODIFICATIONS OR ADDITIONS MAY BE
MADE TO THE SMARTFOAM PORPORTIONING
SYSTEM
WITHOUT PRIOR WRITTEN PERMISSION
FROM:
HALE PRODUCTS, INC
607 NW 27th Avenue
Ocala, Florida 34475 USA
Telephone: [phone]
FAX: [phone]
❑All electrical systems have the potential to
cause sparks during service. Take care to
eliminate explosive or hazardous environments
during service and/or repair.
❑Toprevent electrical shock always disconnect the
primary power source before attempting to service
any part of the Hale Foam system.
❑Toprevent system damage or electrical shock
the main power supply wire is the last
connection made to the Hale Foam motor
controller.
❑Release all pressure then drain all concentrate and
water from the system before servicing any of its
component parts.

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SmartFOAM
❑Do not operate system at pressures higher than the
maximum rated pressure.
❑Use only pipe, hose, and fittings from the foam
pump outlet to the injector fitting, which are rated at
or above the maximum pressure rating at
which the
water pump system operates.
❑Hale Foam proportioning systems are designed for
use on negative ground direct current electrical
systems only.
❑Do not mount radio transmitter or transmitter
cables in direct or close contact with the
SmartFOAM control unit.
❑Before connecting the cord sets and wiring
harnesses, inspect the seal washer in the female
connector. If the seal washer is missing or damaged,
water can enter the connector causing corrosion of
the pins and terminals. This could result in possible
system failure.
❑Always disconnect the power cable, ground
straps, electrical wires and control cables from
the control unit or other Hale Foam system
equipment before electric arc welding at any point
on the apparatus Failure to do so could result in a
power surge through the unit that
could cause
irreparable damage.
❑DO NOT connect the main power lead to small leads
that are supplying some other device, such as a light
bar or siren.
❑When operating the Hale SmartFOAM in Simulated
Flow mode, an outlet for the foam concentrate must
be provided to prevent excessive pressure build up
in the discharge piping or hoses.
❑Make sure the foam tank and foam concentrate
suction hoses are clean before making final
connection to foam pump. If necessary, flush tank
and hoses prior to making connection.
❑Check all hoses for weak or worn conditions after
each use. Ensure that all connections and fittings
are tight and secure.
❑Ensure that the electrical source of power for the
unit is a negative (–) ground DC system, of
correct input voltage, with a reserve minimum
current available to drive the system.
❑The in-line strainer/valve assembly is a low
pressure device and WILL NOT withstand
flushing water pressure in excess of 45 PSI (3
BAR).
❑When determining the location of Hale Foam
system components keep in mind piping runs,
cable routing and other interferences that
could
hinder or interfere with proper system
performance.
❑Always position the check valve/injector fitting at
a horizontal or higher angle to allow water to
drain away from the fitting. This avoids the
possibility of sediment deposits or the formation
of an ice plug.
❑The cord sets provided with each Hale Foam
system are indexed to ensure correct receptacle
installation (they insert one way only). When
making cord set connections DO NOT force
mismatched connections as damage can result in
improper system operation.
❑Make sure all connections are sound, and that
each connection is correct.
❑The cables shipped with each Hale Foam system
are 100% tested at the factory with that
unit.
Improper handling and forcing connections can
damage these cables which could result in other
system damage.
❑There are no user serviceable parts inside Hale
Foam system electrical/electronic components.
Opening of the motor controller or controller unit
voids the warranty.
❑Use mounting hardware that is compatible with all
foam concentrates to be used in the system.
Use
washers, lock washers and cap screws made of
brass or 300 series stainless steel.
❑When making wire splice connections, make sure
they are properly insulated and sealed using an
adhesive filled heat shrink tubing.
❑ALWAYS connect the primary positive power lead
from the terminal block to the master switch
terminal or the positive battery terminal.
❑Use a minimum 8AWG type SGX (SAE J1127)
chemical resistant battery cable and protect with
wire loom.
❑Prevent corrosion of power and ground connections
by sealing these connections with silicone sealant
provided.
❑Prevent possible short circuit by using the rubber
boot provided to insulate the primary power
connection at the Hale SmartFOAM motor
controller.

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SmartFOAM
SYSTEM INSTALLER START-UP
On initial power-up of the Hale SmartFOAM system at
the installer facility, the following procedures must be
followed.
INITIAL SYSTEM POWER CHECK
Watch the display on the controller unit as the apparatus
electrical system is turned ON. Check the controller unit
readout for:
❑SmartFOAM booting screen is shown for three
seconds.
❑SmartFOAM splash screen is shown for three
seconds.
❑SmartFOAM version screen is shown for two
seconds.
❑SmartFOAM preset screen is shown (default)
OR
SmartFOAM classic FoamLogix screen is
shown.
(The screen shown depends on the “display
format” chosen in the user menu).
(See Figure 44: Controller Unit Initialization).
If a default display does not appear, refer to the
TROUBLESHOOTING section for possible WARM-UP/
SYSTEM CHECKING causes and solutions.
INITIAL SYSTEM CHECK
After initial system power-up the low tank level sensor
operation, foam pump operation, and flow sensor
calibration must be checked per the following:
CAUTION!
WATER IS USED AT THE SYSTEM INSTALLER
FACILITY TO VERIFY LOW TANK LEVEL SENSOR
SYSTEM READY OPERATION AND FOAM PUMP
OPERATION AS THE END USER SPECIFIED FOAM
CONCENTRATES MAY NOT BE READILY
AVAILABLE.
DO NOT PUMP WATER WITH THE HALE FOAM-
LOGIX FOAM PUMP FOR MORE THAN ONE (1)
MINUTE. DO NOT ATTEMPT TO CALIBRATE FOAM
PUMP FEEDBACK SENSOR WITH OTHER THAN
END USER SPECIFIED FOAM CONCENTRATE.
MAKE SURE THE BYPASS VALVE IS IN THE
BYPASS POSITION WHEN PUMPING WATER WITH
THE FOAM PUMP.
Figure 1: Controller Unit Initialization

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SmartFOAM
Upon initial power-up with the foam tanks empty, the
display on the controller unit will display a warning bar
indicating that the foam tank is low.
Figure 2: Low Foam Tank Warning
1. Fill the foam concentrate tank with WATER. The
“low foam tank” warning indication clears from
the display indicating the low tank level sensor is
operating properly.
2. Place the bypass valve’s handle to the BYPASS
position to check the foam pump operation.
Place a calibrated five gallon container at the
discharge end of the bypass hose.
3. Place the system in simulated flow mode:
a. Press the MENU button.
b. In the menu select the “simulated water
flow” button.
c. In the simulated water flow screen press
the ON/OFF button to toggle simulated
water flow. The icon indicates the
current state.
d. Set the simulated flow to 100 GPM by
using the INCR/DECR buttons.
e. Press the MENU button to return to the
menu.
f. Press the RETURN button to return to
the operation screen.
Figure 3: Setting Simulated Water Flow

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SmartFOAM
Figure 4: SmartFOAM Buttons and Indicators
4. Set the foam injection rate to 1.0% by pressing
the INCR or DECR arrow buttons.
5. Press the ON/OFF button to energize the Hale
SmartFOAM system.
a. The Pump Speed bar graph will
increase to indicate the motor is
running.
b. Observe the discharge at the bypass
hose to make sure the foam pump is
operating.
6. After one minute press the ON/OFF button again
to stop the foam pump. Approximately one
gallon (3.8 liters) of water should discharges into
the container. The TOTAL FOAM display reads
approximately 1.00.
7. Exit simulated water flow. Use the steps
described in step 3 and Figure 46: Setting
Simulated Water Flow.
8. Drain water from the foam tank and concentrate
lines and return the bypass valve’s handle to the
INJECT position.
9. Verify operation of the flow sensor. Also
calibrate the flow sensor using the calibration
procedures. See “User Calibration”.
This completes the Hale SmartFOAM system operation
checks accomplished at the system installer facility.
Foam pump feedback calibration along with setting of
user specified default simulated flow and concentrate
injection rates should be accomplished upon delivery to
the end user using actual end user specified foam
concentrates and default values.

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SmartFOAM
System Setup:
Enter the OEM screen
1. Press the MENU button to go to the system
menu.
2. Press the Calibration/Configuration button on the
system menu screen.
3. Use the touch screen keypad to enter the
password 2314.
a. Press the “Enter” touch screen button to
submit the password.
b. Press the “Delete last digit” touch screen
button to erase the last digit entered.
c. Press the “Delete all digits” touch screen
button to erase all of the digits entered.
4. System settings will need to be set for your
configuration including:
a. Foam System Control
i. Single, Dual Parallel, Dual Series
b. Foam Pump Model:
i. Piston Pumps: 1.7, 2.1
ii. Gear Pumps: 3.3, 5.0, 6.5
c. Tank Selector:
i. None, MST, MDT, ADT
d. Other settings can be changed adjusted
as desired.

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SmartFOAM
1. Use the touch screen keypad to enter the
password 2314.
a. Press the “Enter” touch screen button to
submit the password.
b. Press the “Delete last digit” touch screen
button to erase the last digit entered.
c. Press the “Delete all digits” touch screen
button to erase all of the digits entered.
2. System settings will need to be set for your
configuration including:
a. Foam System Control
i. Single, Dual Parallel, Dual Series
b. Foam Pump Model:
i. Piston Pumps: 1.7, 2.1
ii. Gear Pumps: 3.3, 5.0, 6.5
c. Tank Selector:
i. None, MST, MDT, ADT
1. Use the touch screen keypad to enter the
password 66867.
a. Press the “Enter” touch screen button to
submit the password.
b. Press the “Delete last digit” touch screen
button to erase the last digit entered.
c. Press the “Delete all digits” touch screen
button to erase all of the digits entered.
2. System settings will need to be set for your
configuration including:
a. Use the Up and down arrows to select the
pump model and voltage of the truck/unit.
b. Hit the save button on the right side of the
display

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SmartFOAM
The preset and operation screens:
The SmartFOAM controller will show the PRESET screen after a power cycle. This allows the user to select a preset with
which to start operation. Pressing a preset button will automatically change the view to the OPERATION screen.
The OPERATION screen shows the operational information for the foam system including the buttons and indicators used to
control the system.
Press the HOME button to toggle between the OPERATION and PRESET screens.

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SmartFOAM
To place the system in simulated flow
mode:
1. Press the MENU button.
2. In the menu select the “simulated water flow” button.
3. In the simulated water flow screen press the ON/OFF
button to toggle simulated water flow. The icon
indicates the current state.
Simulated flow is currently OFF
Simulated flow is currently ON
Set the simulated flow to desired rate by using the
INCR/DECR buttons.
Press the MENU button to return to the menu.
4. Press the RETURN button to return to the operation
screen.
5. The operation page shows the simulated water flow in
orange.
Modify the simulated flow rate by using the orange
INCR/DECR buttons on the right side of the display.

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SmartFOAM
Foam calibration:
Enter the foam calibration screen
3. Press the MENU button to go to the system menu.
4. Press the Calibration/Configuration button on the
system menu screen.
5. Use the touch screen keypad to enter the password
1560.
a. Press the “Enter” touch screen button to
submit the password.
b. Press the “Delete last digit” touch screen
button to erase the last digit entered.
c. Press the “Delete all digits” touch screen
button to erase all of the digits entered.
Calibrate the foam
1. Place a graduated measure container at the outlet of
the bypass hose capable of containing the expected
volume of foam concentrate.
2. Start the Hale SmartFOAM foam pump by pressing
the Start/Stop button.
3. Watch the level of foam in the graduated measure
container and stop the foam pump when at the
desired level by pressing the Start/Stop button again.
4. Adjust the reading in the foam total display to match
the actual volume by using the INCR and DECR
arrow buttons.
5. Press the SAVE button.
6. Repeat the procedure to verify that the setting is
correct.
7. Press the MENU button to exit the foam calibration
screen.

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SmartFOAM
INSTALLATION AND DELIVERY CHECKLIST
After the Hale SmartFOAM system is installed, use the following check list to verify installation and ensure proper system
setup when the apparatus is delivered to the end user.
INSTALLATION
Date
Initials
Checklist item
❑System properly installed. (“Start-Up Check List”)
❑Tank level sensor function verified. (“System Installer Start-Up”)
❑Foam pump operation checked. (“System Installer Start-Up”)
❑Foam tank and hoses drained of water. (“System Installer Start-Up”)
❑Flow sensor function checked and calibrated. (“User Calibration”)
DELIVERY
Date
Initials
Checklist item
❑Foam tank filled with user specified foam concentrate. (Complies with Hale
approved concentrate compatibility list.)
❑Foam pump priming checked.
❑Water flow sensor calibration verified with Pitot and smooth bore nozzle.
❑Default simulated water flow value set to end user specification.
❑Foam preset text and injection rates set to end user specification.
❑Foam concentrate feedback value verified and calibrated with end user specified
foam.
❑Proper Hale SmartFOAM system operation demonstrated to end user in accordance
with manual procedures.
❑End user trained in proper operation of Hale SmartFOAM system in accordance with
manual procedures.
❑Warranty registration card filled out by end user and mailed to Hale Products.
❑Two copies of Description, Installation, and Operation manual provided to end user.

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SmartFOAM passwords
Menus
1849 - User menu
2314 - OEM menu
57643 - Factory menu
Set-up
1023 - Preset configuration
6679 - Water calibration (primary paddlewheel)
9766 - Direct water calibration (primary paddlewheel)
6681 - Water calibration (secondary paddlewheel)
1866 - Direct water calibration (secondary paddlewheel)
1560 - Foam calibration
9999 - Maintenance interval screen for resetting intervals
66867 - Motor driver set-up. Sets the motor driver to a specific current range (i.e. 3.3 12V, etc)
5804 - Load all defaults
Debugging
3564 - Download the data logger