Hypro Turbo Stream 1508B-130EFS Use and care manual

5/11 Rev. B
Form L-1530
Turbo Stream®
Installation, Operation, Repair and Parts Manual
Description
The Hypro High Pressure System is a gas motor-driven,
flow-based proportioning system that injects foam concen-
trate at a desired percentage at a fixed water flow rate. The
basic Hypro High Pressure System is shown below. The
system will accurately deliver from 0.3% to 3.0% foam con-
centrate at the rated system pressure and flow rate. The
system will accurately inject foam concentrate while the
system is running at recommended operating speed and
pressure. Foam percentage indication is instantaneously
given on the foam monitoring panel supplied.
The foam concentrate is directly injected into the system at
the head of the pump. It is then fed as foam solution into
the adjustable foam spray gun.
The pump inlet is equipped with a check valve to prevent
contamination of the water supply.
The Hypro High Pressure Foam System is designed for
Class A foam concentrate (per NFPA 1150) applications
and calibrated for viscosity ranges up to 60 CPS.
Model No. 1508B-130EFS

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6. Always disconnect the power source before
attempting to service any part of the system.
7. Release all pressure within the system before
servicing any of its components.
8. Drain all concentrate and water from the discharge
system before servicing any of its component parts.
9. Periodically inspect all hoses for wear or worn
conditions. Make sure all connections and fittings are
tight and secure.
10. Use pipe, hose and fittings that are rated at or above
the maximum pressure rating at which the water pump
system may operate.
11. The components and fittings used in this system
must be compatible with the foam concentrates used
and pressures at which the pump system operates.
12. CAUTION: ENSURE THAT THE ELECTRICAL
SOURCE OF POWER FOR THE UNIT IS THE
APPROPRIATE 12 VOLT NEGATIVE GROUND DC
SYSTEM.
13. Secure all discharge lines before starting the pump.
An unsecure line may whip, causing personal injury
and/or property damage.
14. Any electrical system has the potential to cause
sparks during service. Take care to eliminate
explosive or hazardous environments during service
and repair.
15. CAUTION: Do not attempt to operate the system at
or above a temperature of 130°F (55°C).
16. CAUTION: Periodically inspect the pump and the
system components. Perform routine
maintenance as required. Failure to perform
routine maintenance may cause damage to
individual system components; pump, motor, and
gearbox assemblies. See the maintenance section
of this manual for recommended maintenance
procedures and intervals between maintenance
work.
17. CAUTION: Read and understand “Operating
Instructions” section before attempting to operate
the unit.
18. CAUTION: The components shipped with each
Hypro unit are tested at the factory. Improper
handling and forcing connections can damage the
components which could result in other system
damage.
Notes are used to notify of installation, operation, or
maintenance information that is important but not
safety related.
Caution is used to indicate the presence of a hazard,
which will or may cause minor injury or property
damage if the notice is ignored.
Warning denotes that a potential hazard exists and
indicates procedures that must be followed exactly to
either eliminate or reduce the hazard, and to avoid
serious personal injury, or prevent future safety
problems with the product.
Danger is used to indicate the presence of a hazard
that will result in severe personal injury, death, or
property damage if the notice is ignored.
1. WARNING: Use pressure relief device on the
discharge side of the pump to prevent damage
from pressure buildup when the pump discharge
is blocked or otherwise closed and the power
source is still running. For trigger gun operation,
or where discharge is frequently shut off, pressure
unloader valves are recommended. The Turbo
Stream system is equipped with a pressure relief
device and should not be removed.
FAILURE TO FOLLOW THIS WARNING MAY
RESULT IN PERSONAL INJURY AND/OR
PROPERTY DAMAGE AND WILL VOID THE
PRUDUCTION WARRANTY.
2. WARNING: Do not pump flammable or explosive
fluids such as gasoline, fuel oil, kerosene, etc. Do
not use in explosive atmospheres. The pump
should be used only with liquids that are
compatible with the pump component materials.
Failure to fallow this warning may result in
personal injury and/or damage and will void the
product warranty.
3. Do not pump at a pressure higher than the maximum
recommended pressure [1450 psi (100 BAR)].
4. Do not run the system at greater than recommended
capacity.
5. Do not permanently remove or alter any guarding
devices or attempt to operate the system when these
guards are removed.
General Safety Information
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System Component Description
The following components are packaged with the Model 1508B-130EFS Hypro High Pressure System:
Foam Concentrate Strainer
Inlet Water Strainer
Pump/Motor Assembly
Foam Spray Gun/Wand
Control Panel
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Installer Supplied Parts
The Hypro High Pressure System is provided with the
major components and accessories required for installa-
tion. Due to differences in chassis and apparatus configura-
tions, the installer must provide plumbing to satisfy individ-
ual installation requirements. The following paragraphs list
the specifications for selection of these components.
Before beginning system installation, read this section thor-
oughly to make sure the proper components are selected.
For detailed system installation instructions, refer to Pages
5and 6.
Suction Lines
Corrosion-resistant fittings and hoses from the foam tank to
the foam concentrate inlet of the pump must be used. Use
5/16-inch minimum inside diameter hose for the foam inlet.
Corrosion-resistant fittings and hoses from the water
source to the inlet of the pump must be used. Use only 3/4-
inch minimum inside diameter hose for the water inlet. Use
components that are rated for 23 in [584.2 mm] Hg vacuum
and 50 psi [3 bar] pressure or greater for all suction line
inlets. The components used must be compatible with all
foam concentrates to be used. All fittings used must be
made of brass, 300 series stainless or other corrosion-
resistant materials. Before selection of components, check
for compatibility with foam concentrate. The use of clear
suction hose is recommended to allow viewing of foam and
water priming operations. The pump must be positioned to
allow gravity feed from the foam tank and water source or a
net positive suction head (NPSH) is required.
Discharge Lines
Fittings and hoses from the foam solution discharge of the
pump to the foam spray nozzle must be supplied by the
installer.Hose end fittings on gun and pump are 1/2-inch
[12.7 mm] NPT. Hose lengths and sizes are shown below.
All hoses must be rated for 1800 psi [124.1 BAR] minimum
working pressure. Fittings and hoses must be compatible
with all foam concentrates to be used. Use fittings of brass,
300 series stainless or other corrosion-resistant material
that is compatible with foam concentrates to be used.
Thermal relief valve must be plumbed to discharge away
from operator.
Check Valves
Check valves have been included with the system at the
water inlet to help prevent back flow of foam concentrate or
foam solution. The system should be disconnected from
exterior water supplies when not in use. A complete system
flush should be performed before storage to prevent com-
ponent failure due to evaporation of foam and water within
the system.
Foam Concentrate Tank
A foam concentrate tank must be supplied to suit the
capacity required for the apparatus application. The tank
should meet NFPA minimum standards for the design
capacity, including filler size, venting and drain facility. A
shut-off valve is recommended to allow cleaning of the
strainer.
Electrical Requirements
Electrical wiring must be supplied to the engine starter
switch. SEE ENGINE MANUAL for detailed electrical hook
up specifications.
CAUTION: Always disconnect ground before electrical
arc welding on any Hypro equipment. Failure to do so
will result in a power surge through the system that
could case irreparable damage to the electronic com-
ponents.
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Because of the potential differences in apparatus plumbing
and foam system configuration, it is not practical to depict
exactly how each Hypro unit can best be installed onto a
particular apparatus. Most of the information contained in
the following sections, however, will apply to any situation.
It is recommended that you read the following sections
thoroughly before beginning installation of the Hypro sys-
tem. It is also recommended that you spend time planning
and designing where and how you intend to install this unit
in the apparatus before beginning the actual installation.
Determine the location of the components to be installed
such as: foam tank, water tank, foam system, and display
panel. Try to position the components to minimize fittings
and hose lengths. Position the system in an accessible
area.
The foam system should be positioned below the foam
tank discharge to allow gravity feed to the pump. Place the
foam tank where refilling with 5 gallon [19 liter] containers
and other methods is suitable for the end user. The water
inlet pressure must not exceed 3 psi [0.21 bar].
Determine a location for the display panel on the unit that
is visually accessible while the system is in operation. The
display panel should be located on the same horizontal
plane as the system and foam tank.
Determine a safe place for the thermal relief valve drain
hose, and be sure it drains in a safe location away from
operator.
Installation Planning
Plumbing Component Installation
The following diagram (Figure 1) provides recommended guidelines for the location of the system components that handle
foam concentrate, water, and foam solution.
Foam
Tank
Water
Tank
Water Shut-Off
Valve
Water Inlet Strainer
Pump/Gearbox Assy
Gas Engine
Foam Spray Gun
Foam
Adjustment &
Flowmeter
Foam Inlet Strainer
Figure 1 Hypro High Pressure System Plumbing
L-1530 (5/11 Rev. B)

Pump/Motor Base Assembly
The pump/motor base assembly must be mounted in the
horizontal position. The system can be run at 15 degrees
on any plane to the horizontal and may be run intermittent-
lyat 30 degrees to the horizontal plane. The base of the
system must be anchored to a surface or structure that is
ridged and of adequate strength to withstand the vibration
and stresses of apparatus operation. The drawings on
page 10 provide the mounting dimensions for the Hypro
High Pressure pump/motor base assembly. Flexible hose
is required to make the hose connections to the Hypro
High Pressure System. DO NOT hard pipe the system.
Protect the hoses and wiring to prevent chafing and abra-
sion during operation of the foam system. Protect the foam
pump base unit from excessive spray and debris. See
engine manual for allowed engine operating conditions.
Line Strainers
There are two line strainers provided with theTurbo Stream
unit. The pump inlet line strainer has 3/4-inch NPT female
threaded ports and is to be installed on the water inlet of
the foam pump. The water supply hose should have ade-
quate wall stiffness to withstand the vacuum of the pump
while it is in operation (23 in. [584 mm] Hg and 50 psi [3
BAR]).
NOTE:If a pressurized water flush from one of the dis-
charges is incorporated, the plumbing and line strainer
exposed to this pressure must be rated at or above the
operating pressure of all other discharge components
(1800 psi [124.1 BAR] minimum).
Check Valves
A 3/4-inch check valve is included at pump inlet. A foam
injection check valve is included.
Flushing System
Depending on the corrosiveness of the foam concentrates
to be used, a flushing system may be required in the foam
concentrate injection system. Most Class A foam concen-
trates (per NFPA 1150) are less corrosive and therefore
may not require flushing. It is important to flush and drain
the entire system before long periods of storage to prevent
component malfunction.
Thermal Relief Valve
A thermal relief valve is included with the system to pre-
vent pump overheating during unloading.
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Plumbing Component Installation - continued
Electrical Equipment Installation
Making Sure Everything is Working Right
Electrical Connections
See engine manual for detailed electrical connections only if engine is equipped with electric start.
System Check
Check fuel level and oil level per engine manual prior to running system. Check pump and gear case oil level prior to running
system. Pump and gear case should be filled with oil per manual instructions.
Check the function of all components before using the system. Also check that all plumbing and components are tight and
functional.
Check to see that water supply lines, strainers and foam tank lines are free of debris and plumbed correctly.Any leaks in the
system will cause poor system performance and operation.
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Calibration & Setup
Calibration
The Hypro High Pressure System has been calibrated at
the factory. To check calibration of the system, the following
procedure should be used:
1) Start the system. Run the engine to an RPM that pro-
duces 8 GPM (3345 Engine RPM) of pump water inlet
flow. Tools needed for the test are a pitot tube or other
calibrated flowmeter to test the system inlet water flow,
agraduated bucket to remove and calibrate foam con-
centrate, and a stop watch to measure volume unit/time
of foam concentrate and water flow.
2) Open the control knob of the display panel to start foam
injection, while holding the spray gun in the on position,
run the system for a few minutes. The system will not
inject foam concentrate while the system is unloading.
3) Turn the injection control knob to the desired foam
injection calibration point. Start the stop watch and
record the necessary volumes or flow rates of foam
concentrate and water.
4) Measure the amount of foam concentrate in the con-
tainer and compare that to the calculated amount.
(Main flow rate X injection rate X minutes flowed
[8.00 GPM X 0.005 (0.5%) injection rate X 5 minutes =
0.20 gallons]).
5) CAUTION:Long periods of pump deadheading may
result in pump damage due to overheating of water in
the system. The system is equipped with a thermal
relief valve to eliminate damage to the pump during
unloading. It is recommended to idle down the system
during unloading if the system must stay running during
transportation.
6) CAUTION:System may only be calibrated with Class
Afoams with a viscosity from 10-60 CPS. Use of other
lower or higher viscosity Class Afoams will create error
in calibration and setup. Use only quality Class A
foams.
7) Measure the amount of concentrate injected over time
and compare to the level indicated on the display panel
during this time. The output of the Hypro High Pressure
System must be set at a constant 8 GPM + 0.20 GPM/
-0.5 GPM. Injection rate is easily changed by turning
the foam % control knob on the display panel. The foam
percentage is indicated on the display panel and is read
using the largest diameter of the foam percent float.
Repeat at each indicated % if desired.
8) The water inlet flow rate may be adjusted by changing
the engine RPM. Increasing the engine RPM will
increase the flow rate. Decreasing the engine RPM will
decrease the water inlet flow rate. Varying engine RPM
will change calibration settings.
NOTE: The viscosity of different foam concentrates may
have an effect on the amount of foam concentrate that is
injected into the water stream. When calibrating the system,
use the foam concentrate that will be used most frequently
during normal operations. When different viscosity foam
concentrates are used, the actual concentrate injection may
vary as much as 100%.
Pressure Relief Valve Adjustment
The pressure relief valve is factory tested and preset at
1800 psi [124.1 BAR]. During normal operation, the relief
valve will not require adjustment. The following procedures
are provided if adjustment is necessary in field installation.
DO NOT set the relief valve above 1800 psi [124.1 BAR].
1) Start the system and run the engine to maximum RPM
while turning the foam spray gun to the on position.
2) Turn off the foam spray gun. The relief pressure will be
indicated on the provided pressure gauge as the relief
valve functions.
3) If required, adjust the relief valve by turning the adjuster
clockwise to increase relief valve pressure and counter-
clockwise to decrease pressure.
4) Repeat above steps as needed.
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Operating Instructions
Preparations Before Starting the System
1) Fuel: Check fuel level in tank. Do not overfill tank. Use
fresh, clean automotive fuel. NOTE: DO NOT FILL
FUEL TANK WHEN ENGINE IS RUNNING.
2) Engine Oil: Before checking or refilling with engine oil,
make sure the engine is stopped and placed on a sta-
ble, level surface. Use oil recommended for ambient air
temperatures at which the engine will be running.
Change oil according to manufacturer’s recommenda-
tion. (At least once after the first 20 hours and every
100 hours thereafter.)
3) Pump Oil: Before checking or refilling with pump oil,
make sure the engine is stopped and placed on a sta-
ble, level surface. Use oil recommended for ambient air
temperatures at which the pump will be running.
Change oil according to manufacturer’s recommenda-
tion, using SAE 30 weight non-detergent oil. Check oil
level before running the system using the oil level dip
stick on the pump.
4) Gear Case Oil: Before checking or refilling with gear
case oil, make sure the gear case and engine are
stopped and placed on a stable level surface. Use oil
recommended for ambient air temperatures at which
the gear case will be running at. Change oil according
to manufacturer’s recommendation, using SAE 90
weight non-detergent oil. Check oil level before running
the system using the oil level hole on the side of the
gear case.
5) Check to see that water supply lines, strainers and
foam tank lines are free of debris and plumbed correct-
ly. Any leaks in the system will cause poor system
performance and operation.
Starting the System
IMPORTANT: Before starting engine, be sure discharge
hose is secure.
1) Turn the engine switch located by the recoil starter to
the ON position.
2) Turn the fuel cock to the ON position.
3) Push the throttle lever to a slightly open position.
4) Operation of the choke lever
a) When engine is cold:
i) In cold weather, start engine with choke in the
fully closed position.
ii) In warm weather, start engine with choke in
half-closed position.
b) When engine is warm:
i) Start engine with choke in fully open position.
5) Start the engine with electric start key or recoil starter.
Operation of the System
1) Idle the engine for 3 to 5 minutes or until operating tem-
perature is achieved.
2) CAUTION: Do not run the Hypro High Pressure
System for long periods during unloading. Long periods
of pump deadheading may result in pump damage due
to overheating of water in the system.
3) Open the throttle lever to the upper zone after engine
has reached operating temperature.
4) Once the system is primed, you will note a load on the
engine; adjust RPM to proper speed for your pumping
application.
5) Adjust the foam concentrate injection percentage with
the display panel to the desired percentage while the
system is running at full capacity (8 GPM).
Stopping the System
1) Stop pump for a short time:
a) Run throttle all the way down (fully to the right).
b) Turn engine switch to OFF position.
2) Stopping pump for storage:
a) Turn fuel cock to OFF position instead of turning
the engine off.
b) Let the engine idle for 2 to 3 minutes until fuel in
the carburetor is depleted and engine stops.
c) Drain the pump and flush pump after use.
d) Drain all fuel from engine.
e) Store system in clean, dry environment.
Transporting the System
1) Secure gun, hose, tank lids, and other system equip-
ment prior to transport.
2) Turn fuel cock on engine to OFF position prior to trans-
port. Failure to do so may result in flooding of the cylin-
der and contamination of the crankcse oil with gasoline.
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Maintenance
Troubleshooting
1. Daily: Inspect wiring, hoses, pump, gear case, engine
and connectors for tightness, corrosion, leaks and/or
damage.
2. Daily: Check engine oil level and refill as necessary.
3. Monthly: Remove and clean the foam and pump inlet
strainer screens. Flush as required.
4. Monthly: Check pump gear case oil level and refill as
necessary.
5. Monthly: Check gear case oil level and refill as neces-
sary.
6. Monthly: Change engine oil every month or every 100
hours, whichever comes first.
First oil change is to be done at 20 hours.
7. Annually: Drain the pump oil and refill pump gear case
with SAE 30 weight non-detergent oil. Check for foreign
materials in the drained oil (water or debris).
Note: Water quality, flushing and storage techniques,
environment and usage may have an effect on your
maintenance schedule. To ensure equipment longevity,
it is recommended to adjust your schedule accordingly.
Caution: Release all pressure and drain all concentrate
and water from the system before servicing any of its
components.
These Turbo Stream systems are designed to be easy to diagnose and service. There are several major components.
Servicing the system involves isolation of the failed component and replacing it. There are no user serviceable internal
components.
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Installation Drawings
21.44 31.31
17.94
Pulse Hose Connection
Foam Concentrate Inlet
3/8-18 NPT
Water Inlet Port
3/4-14 NPT
Solution Outlet
1/2-14 NPT
6.69
5.31
.38
.22 Dia (4)
2.25
3
.44 Dia (6 Holes)
18.25
5.62
2.63
7.68
3.75
L-1530 (5/11 Rev. B)