Safe Fleet FoamPro Accumax II Fury Guide

MAX100/200-OPERATION Rev200813
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AccuMax II Fury/Fusion
Foam Injection System
--- Vehicle Mounted & Fixed Systems ---
Document Number:
XE-MAX1PM-OPERATION-R0A
Unit
Serial
Number
All quality FoamPro products are ruggedly designed, accurately machined, carefully assembled, thoroughly inspected and 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 CORRESPONDENCE.
FoamPro • 26 Southern Blvd. • Nesconset, NY 11767 USA • 800-533-9511 • FAX [phone]
MODEL MAX100
MODEL MAX200
OPERATION, SET-UP, CALIBRATION, SERVICE & PARTS MANUAL
Pumper Systems
Level #1–500 to 1250 GPM
Foam Pro Models: #3020, #3040, #3060, #3090
Industrial Pumpers and Fixed Systems
Level #2:–1500 to 2500 GPM: Models #3150 & #3300
Level #3–3000 to 6000 GPM: Model #3300

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1. CONTENTS
Table of Contents
1. CONTENTS..................................................................................................................................2
2. SAFETY........................................................................................................................................3
Safety Precautions........................................................................................................................3
3. INTRODUCTION ........................................................................................................................4
Overview: How the Foam System Works....................................................................................4
4. FOAM SYSTEM DRAWINGS – BASIC ...................................................................................6
Basic Drawings for Each System.................................................................................................6
5. DISPLAYS AND CONTROLS—ACCUMAX............................................................................9
Fury, Fusion and APEX Displays ................................................................................................9
Fury Specications.....................................................................................................................10
Fusion Specications ................................................................................................................. 11
APEX Specications..................................................................................................................12
6. FOAM SYSTEM AUXILIARY FUNCTIONS .......................................................................... 13
Final Installer Mobile System: Mobile System Auxiliary
Foam Functions....................................................................................................................13
7. OPERATION OF SYSTEM .......................................................................................................17
Screen Overview........................................................................................................................ 17
Screen View ...............................................................................................................................19
Accessing Water Flow Simulation Mode...................................................................................26
8. SETUP ........................................................................................................................................27
Setup Guidelines ........................................................................................................................27
Table 1. AccuMax System Setup Process .......................................................................................28
User Access Level......................................................................................................................29
9. USER SETTINGS ......................................................................................................................38
Adjusting User Settings ............................................................................................................. 38
Display .......................................................................................................................................47
Report Functions........................................................................................................................ 49
Event Log Functions..................................................................................................................51
10. FACTORY SETTINGS.............................................................................................................53
Changing Factory Settings......................................................................................................... 53
11. DIAGNOSTICS, TROUBLESHOOTING AND TESTING ....................................................55
Diagnostics Tools.......................................................................................................................55
Active Error/Warning.................................................................................................................57
Error/Warning Codes Troubleshooting Table ............................................................................58
Table 2. Error/Warning Codes ........................................................................................................58
12. CALIBRATION & TESTING ..................................................................................................63
Calibration Procedure Instructions ............................................................................................ 63
Table 3. Calibration Requirements .................................................................................................66
Valve Position Calibration (for MAX200 Fusion models only) ................................................ 74
Water Pressure Calibration (for MAX200 Fusion models only) ...............................................74
13. MAINTENANCE & SERVICE REQUIREMENTS................................................................76
Flushing Kit Maintenance/Service.............................................................................................76
14. COMPONENT DRAWINGS & PART NUMBERS ................................................................ 80
Line Control Assembly Dimensions and Flow Capacities ........................................................80

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2. SAFETY
Safety Precautions
Throughout the AccuMax foam system installation manual, three (3) levels of precautions are denoted
as follows:
Cautions are used to indicate the presence of a hazard, which will or may cause
minor injury or property damage if the notice is ignored.
Warnings denote 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.
Dangers are used to indicate the presence of a hazard that will result in severe
personal injury, death, or property damage if the notice is ignored.
• Before operating an AccuMax Foam Injection System, read all of the following safety precautions and operating manual
following all sections carefully.
• Proper ear protection must be worn while operating rotary gear pumps and foam/re pump systems.
• Proper eye protection is required while operating and maintaining any foam/re pump system.
• The normal ambient operating temperatures for xed and mobile foam system applications could vary from -40°F (-40°C)
to 130°F (54°C). Special provisions shall be provided by the installer for both extremely low or high operating conditions.
• Maximum Operating Temperatures Inside of the Pump Enclosure: 160° F / 70° C.

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3. INTRODUCTION
Overview: How the Foam System Works
The FoamPro AccuMax injection system is an electronically controlled, hydraulically driven, foam concentrate
proportioning system designed to provide the wide range of foam concentrate injection rates necessary for foam operations.
The FoamPro AccuMax system will accurately deliver from 0.1% to 10.0% foam concentrate.
The performance and accuracy of the foam system shall be in compliance to applicable sections of NFPA #1901
(mobile vehicle systems) or NFPA #20 (xed systems). Please note: the installer shall be responsible for nal compliance
of the assembled foam installation, setup, and testing to meet NFPA or 3rd party testing requirements.
The FoamPro AccuMax system is a ow-based proportioning system that measures water ow through specied
discharges or water manifold and injects the correct proportional amount of foam concentrate to maintain the desired
percentage. The basic system is comprised of the following ve (5) assemblies for 1 to 15 foam line injectors and discharges:
a. Hydraulic System: FoamPro shall furnish the hydraulic pump, hydraulic motor, and hydraulic controller shall be supplied
by Foam Pro. The hydraulic cooler and reservoir can be supplied by the nal installer or Foam Pro.
b. Foam System: FoamPro shall furnish foam line Injectors (FLI) for water manifold (single-point) or each discharge
(multi-point), low-ow assembly, Fury or Fusion foam displays, main foam owmeter, foam pressure transducer, FRC
TankVision level display (or optional low-level sensor), and cabling for the foam system.
c. Electrical System: FoamPro shall furnish displays and controls, electrical communication system, and cabling. The nal
installer shall supply power supply fusing and wiring.
d. Foam Pump Components: FoamPro shall furnish foam pump, relief valve, and foam pump inlet wye strainer.
e. Water Discharge Components: FoamPro shall furnish water owmeter & pressure transducer (single-point) or water
owmeters and pressure transducers on each discharge (multi-point). Fusion and APEX systems have Elkhart electric
valves furnished by Foam Pro.
The hydraulic controller operates the hydraulic drive system to supply the proper amount of foam concentrate required
for the AccuMax operation and foam line controllers in use. A ‘wye’ strainer shall be installed before the foam pump to
protect the positive displacement foam pump from debris. A safety pressure relief valve shall be installed downstream of
the foam pump to recirculate foam to the suction side of the foam pump. This relief valve shall be supplied by FoamPro
and approved by the foam pump manufacturer. Hydraulic power to operate the foam pump shall be provided by a separate
hydraulic pump, in mobile systems shall be driven by the transmission mounted PTO and xed systems by an electric
motor or diesel engine. The foam concentrate line (from the foam pump) shall have a pressure transducer to control the
hydraulic system.
The foam line controller (FLI) shall consist of foam owmeter, foam control valve, foam injection check valve, and
a calibrate/inject valve. The AccuMax Fury or Fusion or Fusion/Apex displays communicate the proper information to
ensure the proper amount of concentrate is dispensed to the foam manifold or to the discharge that it controls.
The AccuMax II displays are in constant communication with hydraulic controller, foam line injector (FLI), water
pressure transducer(s), and water owmeter(s) to determine the correct amount of foam concentrate required and to
control the hydraulic pump to provide the hydraulic ow to drive the foam pump to deliver the proper amount of foam
concentrate. Additionally, the AccuMax system monitors the foam ow through the master foam owmeter from the
discharge of the foam pump. The AccuMax Fusion or Fury display menu allows the operator in “menu mode” to display
various functions and settings for foam system operator information.

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The constant comparison of the water ow and foam ow information by the AccuMax system ensures the
desired proportion of foam concentrate, based on water ow rate, independent of any variations in re pump intake or
discharge pressures. As water ow increases or decreases, the foam concentrate rate of injection is increased or decreased
automatically to correspond to water ow, maintaining the proper concentrate percentage as selected on the FLI injector.
It also controls the foam control valve to allow the proper amount of foam concentrate to be injected into water manifold
or individual discharge lines based on the input requirements controlled by the re pump operator and the information
supplied by the foam owmeter(s) and the water owmeter(s) regardless of operating pressure.
Each FLI controller operates independently and all FLI assembly(ies) shall communicate with the AccuMax
software for total system operation. With a single-point FLI, one pressure transducer is provided. On multi-point Fusion
system, a specied number of FLI controllers and water pressure transducers are provided; installed on each discharge
(to indicate discharge “line pressure” readings). Foam concentrate shall be injected directly into the water manifold or
into each discharge of specied foam/water discharges.
The water line owmeter measures the water ow and sends a signal to the display(s). A water pressure transducer
shall be installed on the water manifold (single-point) or each water/foam solution discharge line.
On vehicle mounted systems: 12/24-volt electrical power to operate the foam system shall be provided by the
chassis electrical system.
On xed systems: 12/24-volt electrical power to operate the foam system shall be provided by a separate battery
and charger system by the installer. In both electrical systems, the nal installer shall be responsible for power supply
wiring and fuse protection per the electrical section of the installation manual.

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4. FOAM SYSTEM DRAWINGS – BASIC
Basic Drawings for Each System
Drawing #1–Fury Single-Point
OEM
FOAM TANK
SUMP
3"
3"
11/2"
FIRE PUMP
WATE RWAY
CHECK VALVE
OFF-BOARD PICK-UP
FOAM/WATER
MANIFOLD
WATER MANIFOLD
WATER ONLY DISCHARGES
CALIBRATE/
INJECT VALVE
300 GPM / 1150 LPM
FOAM PUMP
RELIEF
VALVE
FOAM
PUMP
MASTER PRESSURE
TRANSDUCER
MASTER FOAM
FLOWMETER
LO-FLOW RETURN LINE
ON/OFF FOAM TANK TO
FOAM PUMP VALVE
MANUALLY
OPERATED VALVE
LO-FLOW
ASSEMBLY
1.5" OR 2"
FOAM-LINE INJECTOR
ASSEMBLY
STRAINER
PRESSURE
TRANSDUCER
INJECTION CHECK VALVE
TO FOAM TANK OR
CALIBRATE LINE
WATE RWAY
FLOWMETER
FOAM TANK VENT
OPTIONAL CHECK VALVE
SUMP

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Drawing #2–Fury Multi-Point
OEM
FOAM TANK
SUMP
2"
2"
FOAM TANK VENT
FLEXIBLE HOSE SUCTION LINE
AUXILIARY FOAM CONCENTRATE INTAKE
MANUALLY
OPERATED VALVE
OPTIONAL CHECK VALVE
ON/OFF FOAM TANK TO
FOAM PUMP VALVE
STRAINER
300 GPM / 1150 LPM
FOAM PUMP
SIEMENS
FLOWMETER
FOAM
FOAM
PUMP PRESSURE
TRANSDUCER
LO-FLOW
ASSEMBLY
RELIEF
VALVE
FIRE PUMP
WATE RWAY
CHECK VALVE
WATE RWAY
FLOWMETER
FOAM-LINE INJECTORS (6)
4"
MONITOR
FOAM
2.5"
DISCHARGE
4" FOAM
LDH
SUMP
TANKVISION

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Drawing #3–Fusion Multi-Point
OEM
FOAM TANK
SUMP
2"
2"
FOAM TANK VENT
FLEXIBLE HOSE SUCTION LINE
AUXILIARY FOAM CONCENTRATE INTAKE
MANUALLY
OPERATED VALVE
OPTIONAL CHECK VALVE
ON/OFF FOAM TANK TO
FOAM PUMP VALVE
STRAINER
300 GPM / 1150 LPM
FOAM PUMP
SIEMENS
FLOWMETER
FOAM
FOAM
PUMP
PRESSURE
TRANSDUCER
LO-FLOW
ASSEMBLY
RELIEF
VALVE
FIRE PUMP
WATE RWAY
CHECK VALVE
WATE RWAY
FLOWMETER
FOAM-LINE INJECTORS (6)
4"
MONITOR
FOAM
4" FOAM
LDH 2.5"
DISCHARGE
SUMP
TANKVISION

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5. DISPLAYS AND CONTROLS—ACCUMAX
Fury, Fusion and APEX Displays
Color-Coded Rain Guard
Fury, Fusion, and APEX displays shall be equipped with color-coded removable rain guard at the top of each display.
The rain guard deects water and dirt from running down the display. The colors shall comply to NFPA #1901 discharge line
colors. The discharge display color shall match the discharge color (installer responsibility).
Displays: FURY, FUSION, APEX
High brightness LCD screen shall have numerical, alpha, and graphical displays for discharge and foam system operations.
Each display (FURY, FUSION, and APEX) are unique, with various selectable buttons, menus, and functional operations.
System messages and errors are shown through indicators on the display. See further details of the screen elements in the
Operation manual. See further details of the screen elements in the later Sections in the Installation Manual #1 and Operation/
Service/Parts Manual #2.
Foam Delivery ON/OFF Button
The RED button turns foam delivery to the manifold or discharges: ON or OFF. To turn ON or OFF, press and hold
this button for two seconds. When foam delivery is ON, the foam concentrate will be delivered at a specied rate as soon
as water ow from the discharge is detected.
Up/Down Buttons
The YELLOW buttons with UP/DOWN arrows control the foam proportioning rate adjustment either incrementally
higher or lower.
a. When pressed once: a lower (DOWN) and higher (UP) preset for foam proportioning rate will be recalled (if it exists).
b. For ne adjustment of foam proportioning rate: press and hold either the UP/DOWN button. The rate will start to adjust
up/down by 0.1% steps; release this button to stop the adjustment.
c. NOTE: a temporary preset at the current value will be added when the button is released. Presets can be changed, added
or deleted by using USER SETTINGS from the main MENU button.
Select button
When the BLUE ‘SELECT’button is pushed, it changes the data displayed on selectable display located on the bottom
of display screen. The button allows operator to read out values for various system parameters as needed. Additionally, it will
also allow operator to access "Water Flow Simulation Mode". The parameters listed below are selectable with this button
can be customized to operator’s need using USER SETTINGS from the MENU button.
• Foam Total Volume *
• Foam Flow System
• Foam Total Volume System
• Foam Tank Level [1]
• Foam Tank Time to Empty* [1]
• Foam Manifold Pressure
• Water Pressure [2]
• Water Flow *
• Water Total Volume*
• Water Total Volume System
• Water Simulated Flow **
NOTE 1: * enabled to be displayed by default
NOTE 2: ** always enabled
NOTE 3: [1] - for systems equipped with TankVision Foam Tank Gauge
NOTE 4: [2] - Fusion (MAX200 Model Only)
List of Available Parameters that can be Selected:

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Fury Specications
Foam/Water Discharge Control Specications
The Foam Pro AccuMax II Fury foam system shall manage: pin-point foam concentrate injection, continuous
monitoring of both water ow and foam ow, and communications to the hydraulic pump for speed and hydraulic uid
output. The foam/water discharge conguration shall include the following components:
1. FURY Display
2. RED: Foam Delivery ON/OFF button
3. YELLOW: Down button (Adjust to lower preset foam %; press and hold)
4. YELLOW: Up button (Adjust to higher preset foam %; press and hold)
5. BLUE: Select button
6. LIGHT BLUE: Menu button
7. Water Pressure Indicator (PSI/BAR)
8. Water Flow Rate (GPM/LPM)
9. Foam Tank Level Indicator
10. Rain Guard (above display)
11. Foam System ON/OFF Indicator
on Display
AccuMax Fury
2
4
3
5
6
8
10
9
1
7
11