HALE FoamLogix 1.7AHP Operating and installation instructions

FoamLogixTM
Model 2.1Aand 1.7AHP Class “A”
Electronic Foam Proportioning Systems
Description, Installation and
OperationManual
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]
5LR Phone: [phone]
IDEX DINGLEE TECHNOLOGY (Tianjin) Co. Ltd.
No.9, 2nd Haitai Fazhan Road Huayuan Industrial Development Area (outside of ring road)
Tianjin High-Tech Industrial Park Tianjin China
Telephone: [phone]
FAX: [phone]
Manual p/n: 029-0020-74-0-F

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
2
APPARATUS INFORMATION
Hale FoamLogix System Serial Number
In Service Date
Fire Department
Engine Number
Calibration Factors:
Water Flow Factor
ClassA Foam 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.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER IN YOUR CORRESPONDENCE.
ECO NO
REV
CHANGED FROM
BY
DATE
APVD
03-110
A
RELEASED FOR PRINTING
PRW
6/1/2003
MAL
03-215
B
UPDATED FOR DESIGN CHANGE
PRW
6/30/2003
MAL
04-236
C
UPDATE FOR DESIGN CHANGE
LWH
10/05/04
MAL
ECR 2743
D
UPDATE TO INCLUDE 1.7ahp
RLL
1/15/09
DC
E
CHANGE INFO ON FOAM FLOW SENSOR
REPLACEMENT
RLL
8/10/09
DC
F
UPDATED INFORMATION AND DRAWINGS
TO INCLUDE NEW MOTOR DRIVER
JDF
11/1/18
JLS
Manual P/N: 029-0020-74-0, Rev F

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
3
HOW TO USE THIS MANUAL
This manual is divided into seven sections for clarity and ease of use. Each of the following manual sections
can be a stand alone section or can be used in conjunction with each other.
SECTION 1 SAFETY
This section must be carefully read, understood and adhered to strictly by all installer/builders, operators and
service personnel using the Hale FoamLogix 2.1A and 1.7AHP Foam Proportioning Systems. Do not use or
install the system until you have thoroughly read this section. Failure to comply could cause risk of serious
injury to yourself and others, or damage to the system.
SECTION 2 DESCRIPTION
Provides an introduction to the Hale foam proportioning system along with guidelines for designing and
ordering a complete system.
SECTION 3 INSTALLATION
Provides information to assist the OEM with installation and initial setup of Hale foam proportioning systems
on an apparatus.
SECTION 4 SETUP AND CALIBRATION
Is used by the installer and end user for start-up and calibration of the Hale foam proportioning system.
SECTION 5 OPERATION
Is primarily used by the apparatus user for proper operation and maintenance of the Hale foam proportioning
system.
SECTION 6 TROUBLESHOOTING
If a problem developes, see this section for troubleshooting procedures.
SECTION 7 PARTS IDENTIFICATION
Section 7 includes a parts breakdown of the most commonly used parts of the FoamLogix System.

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
4
NOTES

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
5
CONTENTS PAGE
HOW TO USE THIS MANUAL ........................................................................................3
SECTION 1 SAFETY ....................................................................................................................................3
SECTION 2 DESCRIPTION..........................................................................................................................3
SECTION 3 INSTALLATION............................................................................................................................... 3
SECTION 4 SETUP AND CALIBRATION.......................................................................................................... 3
SECTION 5 OPERATION................................................................................................................................... 3
SECTION 6 TROUBLESHOOTING..............................................................................................................3
SECTION 7 PARTS IDENTIFICATION.............................................................................................................. 3
SECTION 1 SAFETY.....................................................................................................11
Guidelines ................................................................................................................................................... 11
SECTION 2 DESCRIPTION...........................................................................................15
Rotary Plunger Pump..................................................................................................................................15
Control Unit..................................................................................................................................................15
Water Flow Sensor......................................................................................................................................15
Feed Back Sensor.......................................................................................................................................15
Low Pressure Strainer.................................................................................................................................16
Table 1: Maximum Foam Solution Flows ..............................................................................................16
Ordering Information ...................................................................................................................................16
HALE FOAM SYSTEM SPECIFICATIONS......................................................................18
Figure 2: Foam Pump Installation Envelope Dimensions ....................................................................19
SYSTEM CONFIGURATION ............................................................................................20
PACKAGE “A” ...........................................................................................................................................20
PACKAGE “B” ...........................................................................................................................................20
Figure 3: Typical Hale FoamLogix 2.1A and 1.7AHP System Layout ....................................................21
Hale FoamLogix 2.1A Foam Proportioner System......................................................................................22
Low Tank Level Sensor Options..................................................................................................................23
Flow Sensors...............................................................................................................................................24
Figure 4: Pipe Size vs. Flow Range.......................................................................................................24
Check Valve Manifolds, Flanges and Gaskets............................................................................................25
Elbows and Mini-Manifolds .........................................................................................................................26
Remote Start Option....................................................................................................................................27
SECTION 3 INSTALLATION................................................................................................29
Foam Pump and Motor Assembly...............................................................................................................29
Control Unit and Instruction/System Diagram Placard................................................................................30
Installer Supplied Components ...................................................................................................................30
Foam Concentrate Suction Hose................................................................................................................30
Recommended Components..................................................................................................................30
Foam Concentrate Discharge Hose............................................................................................................31
Recommended Components..................................................................................................................31
Foam Concentrate Bypass Hose ................................................................................................................31
Recommended Components..................................................................................................................31
Check Valves.............................................................................................................................................................31
Flushing Water Hose...................................................................................................................................32
Foam Discharge Drains...............................................................................................................................32
Freeze Protection........................................................................................................................................32
Electrical Requirements ..............................................................................................................................32
Figure 5: Recommended Relay Wiring Schematic ................................................................................33
Table 6: Recommended Primary Power Cable Sizes.............................................................................33
Foam Concentrate Tank ................................................................................................................................................33

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
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Contents -continued .......................................................................Page
SECTION 3 INSTALLATION Continued
FOAM PUMP MOUNTING........................................................................................................34
Figure 7: FoamLogix Pump Installation..................................................................................................34
PLUMBING INSTALLATION.............................................................................................................34
Figure 8: Base Plate Mounting Hole Locations......................................................................................35
Water and Foam Solution Plumbing............................................................................................................35
Check Valve Manifold..................................................................................................................................35
Figure 9: Check Valve Manifold Installation ...........................................................................................36
Optional Hale Piping Components..............................................................................................................36
“Waterway” Check Valves........................................................................................................................................36
Figure 10: Typical Midship Pump Installation.........................................................................................37
Figure 11: “Typical 4” Check Valve Installation, Midship Pump”.............................................................37
Flow Sensor ................................................................................................................................................38
Figure 12: Flow Sensor Tee Position Range..........................................................................................38
Table 13: Pipe Size vz. Minimum Straight Run .....................................................................................38
Figure 14: Typical Reduced Size Sensor Piping Arrangement ..............................................................39
Figure 15: Flow Sensor Placement........................................................................................................39
Saddle Clamp Installation............................................................................................................................39
Foam Pump Flush System..........................................................................................................................40
Figure 16: Flow Sensor/Saddle Clamp Installation................................................................................40
FOAM CONCENTRATE PLUMBING..........................................................................................................40
Foam Strainer Connection ..........................................................................................................................40
Check Valve/Injector Fitting.........................................................................................................................41
Figure 17: Check Valve Injector Fitting Installation ................................................................................41
Figure 18: Injection and Bypass Hose Connections...............................................................................42
Foam Concentrate Injection Hose...............................................................................................................42
Bypass Hose Connection............................................................................................................................42
ELECTRICAL INSTALLATION.........................................................................................................43
Electrical Connections.................................................................................................................................43
Figure 19: Control Unit Mounting Dimension .........................................................................................44
Control Unit..................................................................................................................................................44
Display Unit Power and Ground Connections.............................................................................................44
Figure 20: Control Harness Connections ...............................................................................................45
Figure 21: System Power and Ground Connections..............................................................................45
Motor Ground/Primary Power .....................................................................................................................46
Ground Connection.....................................................................................................................................46
Primary Power Supply Connection..............................................................................................................46
RFI/EMI............................................................................................................................................................... 46
Figure 22: Extra Cable Storage..............................................................................................................47

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
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Contents -continued ................................................................... Page
START-UP CHECKLIST................................................................................................48
Electrical......................................................................................................................................................48
Liquid...........................................................................................................................................................48
Foam Pump.................................................................................................................................................48
SYSTEM INSTALLER START-UP.......................................................................................49
Initial System Power Check.........................................................................................................................49
Initial System Check....................................................................................................................................49
Figure 23: Control Unit Ready Indication ...............................................................................................49
Figure 24: Simulated Flow Display.........................................................................................................50
INSTALLATION AND DELIVERY CHECK LIST............................................................51
Installation...................................................................................................................................................51
Delilvery.......................................................................................................................................................51
USER CALIBRATION.......................................................................................................53
Entering Passwords ....................................................................................................................................53
Table 25: Password Sequence...............................................................................................................53
Restore Factory Defaults.............................................................................................................................53
Calibration ...................................................................................................................................................53
Figure 26: Display - Password and Calibration Modes ..........................................................................54
Figure 27: Display - Flow Sensor Calibration.........................................................................................54
Flow Sensor Calibration..............................................................................................................................54
Record Flow and Sensor Calibration Factors..............................................................................................55
Figure 28: Display - Flow Sensor Calibration Factor..............................................................................55
Figure 29: Display - Simulated Flow Calibration ....................................................................................55
Simulated Flow............................................................................................................................................55
Foam Concentrate injection Rate................................................................................................................55
Foam Pump Feedback Calibration..............................................................................................................56
Figure 30: Display - Foam Concentrate Injection Rate Default Value.........................................................56
Figure 31: Display - Foam Pump Feedback Calibration.........................................................................56
Figure 32: Foam Concentrate Collection................................................................................................56
Record Foam Pump Feedback Calibration Factor......................................................................................57
Exit and Save Calibration............................................................................................................................57
Figure 33: Display - Foam Pump Feedback Calibration Factor .............................................................57
Figure 34: Display - Exit and Save Calibration.......................................................................................57
Relief Valve................................................................................................................................................................58
English to Metric Units.................................................................................................................................58
Figure 35: Relief Valve.......................................................................................................................................58
To convert to Metric units: ...........................................................................................................................58
SECTION 4 OPERATION............................................................................................................. 59
Description...................................................................................................................................................59
Figure 36: Digital Display Control Unit Overview ...................................................................................59
Display Information......................................................................................................................................60
Control Unit Functions.................................................................................................................................60
Flow.............................................................................................................................................................60

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
8
% Foam.......................................................................................................................................................60
Total Flow ...................................................................................................................................................60
Figure 37: Display - Function Modes .....................................................................................................60
Bar graph.....................................................................................................................................................61
Reset Functions ..........................................................................................................................................61
Foam Concentrate Injection Rate................................................................................................................61
Warning Messages......................................................................................................................................61
Low Foam Tank Level..................................................................................................................................62
Figure 38: Diaplay - Low Foam Tank Display.........................................................................................62
Priming Error...............................................................................................................................................62
High Ambient Temperature ...............................................................................................................................62
Figure 39: Display - Priming Error..........................................................................................................62
Priming the Foam Pump .............................................................................................................................63
Figure 40: Display - High Temperature and Low Battery........................................................................63
NORMAL OPERATION SUMMARY ......................................................................................... 64
SIMULATED FLOW OPERATION............................................................................................. 66
Figure 41: Display - Simulated Flow Operation.....................................................................................66
Simulated flow sequence............................................................................................................................66
To End Simulated Flow................................................................................................................................67
SECTION 5 MAINTENANCE...................................................................................................69
Maintenance Procedures ............................................................................................................................69
Freeze Protection........................................................................................................................................69
SECTION 6 TROUBLESHOOTING ........................................................................................71
User Diagnostics .........................................................................................................................................71
Figure 42: Distribution Box Overview .....................................................................................................71
System Overview ........................................................................................................................................72
Figure 43: FoamLogix 2.1A & 1.7AHP System Closed-Loop Flow Diagram.........................................72
Distribution Box ...........................................................................................................................................72
Pump/Motor.................................................................................................................................................72
Bar Graph....................................................................................................................................................73
Summary.....................................................................................................................................................73
Problem Isolation.........................................................................................................................................73
Troubleshooting charts................................................................................................................................74
Chart 44: Hale FoamLogix System Troubleshooting Flow Diagram ...................................................74
Contents -continued .................................................................................... Page
SECTION 7 ILLUSTRATED PARTS BREAKDOWN................................................................76
General................................................................................................................................................................... 76
Abbreviations.......................................................................................................................................................... 76
Foam Pump Assembly ....................................................................................................................................78
Figure 7-1: Foam Pump Assembly.............................................................................................................79
Foam Flow Meter Assembly............................................................................................................................80
Figure 7-2: Foam Flow Meter Assembly ................................................................................................81
Flow Sensor components................................................................................................................................82
Figure 7-3: Flow Sensor Components........................................................................................................83

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
9
ADDITIONALFOAMLOGIXCOMPONENTS..................................................................................................84
Figure 7-4: Additional FoamLogix Components.........................................................................................85
Figure 7-5: Additional FoamLogix Components.........................................................................................85
FoamLogix 2.1A Pump Repair Kit...................................................................................................................86
APPENDIX A
HALE FOAM CONCENTRATE COMPATIBILITY.....................................................................87
TableA-1: Hale Foam Concentrate Compatibility......................................................................................87
Reference..................................................................................................................................................88
Distribution Box Replacement - Required Checks........................................................................89
Foam Flow Sensor Replacement Instructions................................................................................93
Warranty.............................................................................................................................................................. 95

FoamLogix, Model 2.1A and 1.7AHP Class “A”
Electronic Foam Proportioning Systems
10