Safe Fleet FoamPro 3435-0134 User manual

Models
3435-0134 (12VDC), 3435-0135 (24VDC)
3435-1020 (120VAC), 3435-1021 (240VAC)
INSTALLATION AND
OPERATION MANUAL
Power-Fill Refill System
Form 809
03/20
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.
Unit
Serial
Number
FoamPro • 26 Southern Blvd. • Nesconset, NY 11767 USA • 800-533-9511 • FAX [phone]
A Safe Fleet Brand

A Safe Fleet Brand
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Installation and Operation Manual
TABLE OF CONTENTS
Section Page
1 SAFETY ........................................................................................................................... 3
2 A QUICK LOOK AT HOW THE SYSTEM WORKS.......................................................... 4
3 WHAT YOU GET.............................................................................................................. 4
4 WHAT YOU SUPPLY....................................................................................................... 5
5 PLAN AHEAD................................................................................................................... 6
6 PLUMBING THE SYSTEM................................................................................................7
7 ELECTRONIC COMPONENT INSTALLATION AND HOOK-UP..................................... 8
8 OPERATING INSTRUCTIONS ....................................................................................... 11
9 MAINTENANCE ............................................................................................................. 12
10 TROUBLESHOOTING ................................................................................................... 12
11 PARTS IDENTIFICATION............................................................................................... 14
12 WARRANTY................................................................................................ BACK COVER
NOTE TO SYSTEM INSTALLERS
IMPORTANT: Please provide a copy of the FoamPro manual to the end user of the equipment.
For additional FoamPro manuals, contact by FAX [phone], web site www.foampro.com,
or call 800-533-9511. Request Form No. 809.

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Installation and Operation Manual
Power-Fill System
1. Always disconnect the power source before
servicing any part of the refill system.
2. Release all pressure within the system before
servicing any of its component parts.
3. Drain all liquids from the system before servicing
any of its component parts.
4. Check all hoses for weak or worn conditions
monthly. Make sure that all connections and
fittings are tight and secure.
5. Use inlet pipe, hose, and fittings - from the
panel to the refill pump inlet - that are rated for
23 inches Hg vacuum (584 mm Hg) and 50 psi
(3 BAR) pressure and are compatible with foam
agents.
6. Use discharge pipe, hose and fittings
from the pump outlet to the inlet of the foam tank
that are rated for a minimum of 50 psi (3 BAR)
and are compatible with foam/chemical agents.
7. Any electrical system has the potential to
cause sparks during service. Eliminate explosive
or hazardous environments during service/repair.
8. The components and fittings used in this system
must be compatible with the foam concentrates used
and pressures at which the pump system operates.
9. CAUTION: Do not operate the system at
or above a temperature of 1600F (710C).
10. CAUTION: Make sure the electrical source of
power for the unit is a constant 12 or 24-volt
DC negative ground system for the 3435-
0134 and 3435-0135 truck-mounted systems,
capable of supplying 41 amps minimum. Make
sure the electrical source of power for the
3435-1020 portable unit is a 120 VAC grounded
circuit, capable of supplying 15 amps
minimum. Make sure the electrical source of
power for the 3435-1021 portable unit is a 240
VAC grounded circuit, capable of supplying 10
amps minimum.
11. CAUTION: Periodically inspect foam pump
and all system components. Perform routine
preventive maintenance as required.
12. Avoid spraying water on the pump/motor
assemblies as this could cause short circuits.
13. WARNING: Do not pump flammable or
explosive fluids such as gasoline, fuel
oil, kerosene, etc. Do not use in explosive
atmospheres. The refill system should be used
only with fluids compatible with its component
materials. Failure to follow this warning may
result in personal injury and/or property
damage.
14. Unplug the AC-driven system when not in use.
15. Never pull the cord to unplug the system from
the power source or to move the pump/motor
assembly, as cord, plug, or pump/motor damage
may occur.
16. Never operate unit without the GFI plug.
Please read all of the following safety precautions and
follow them carefully. They are important for personal injury
prevention or damage to the equipment.
1Safety

A Safe Fleet Brand
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Installation and Operation Manual
The Power-Fill foam refill systems provide for
the filling of the foam reservoirs on an apparatus
without manually filling the tanks from on top of the
apparatus. They are available as an on-board DC
powered system with automated panel control or
an off-board AC powered system with a manual
ON/OFF switch.
The DC Power-Fill system provides for an
automatic shut-off mode or a manual refill mode
via a panel-mounted control. Pushing the green
button will start the foam pump/motor in the
automatic refill mode. When the tank is full,
the green light will go on solid. To override the
automatic mode or to run in the manual mode,
push and hold the red button. To stop the
operation, release the red button. Caution must
be taken not to hold the red button too long or the
tank could overfill.
The AC Power-Fill system provides an AC driven
portable foam pump/motor assembly and a visual
interface typically mounted on the apparatus panel.
The foam pump/motor assembly is manually
switched on and off with a momentary on switch
mounted in the power cord. Switching on the pump
will start the refill process. When the tank is full,
an indicator light on the panel will illuminate. An
additional apparatus kit is available for fitting the
plumbing into other apparatus.
Both systems come with a placard, cam lock
fittings for the plumbing outside the apparatus,
foam pump/motor assembly, a refill wand with 6
feet of 1” ID suction hose, and a side-mount level
indicator switch.
2A Quick Look at How the System Works
3 What You Get
Controller
Panel Placard
Flush Valve
Assembly with
Check Valve
Side-Mount
Level Sensor
Pump/Motor Assembly
Refill wand with 6 ft. suction
hose, cam lock fittings
and panel cap
Panel Check Valve
Flow Switch

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Installation and Operation Manual
Power-Fill System
Optional System Accessories Available
Foam Tank(s)
8 gallon, polypropylene
(P/N 1530-0005)
12 gallon, polypropylene
(P/N 1530-0012)
20 gallon, polypropylene
(P/N 1530-0022)
Requires additional hardware for
compliance with the N.F.P.A.
ITEMS NEEDED:
1. All fittings are to be 1” NPT and are to be
compatible with the fluids being pumped
(typically brass and/or stainless steel).
2. Hose on the suction side of the foam pump
to be clear 1” ID suction-type hose rated for
23 inches (584mm) Hg vacuum and 50 psi
(3 BAR) working pressure.
3. Hose on discharge side of foam pump to be
1” ID hose with a 50 psi (3 BAR) minimum
working pressure.
4. Foam tank/tanks with two-way vent, sized to
customer’s specifications.
SYSTEM WIRING
Use the recommended gauge wire specified as
minimum AWG wire. Use wire that is automotive type
and resistant to abrasion and chemicals such as oil and
foam. It is recommended that wiring be bundled with
wire ties and protected with loom.
Vertical-Mount
Level Sensor
(P/N 2510-0028)
4 What You Supply
AC Portable System
Panel placard
with full lamp
Side-mount
level sensor
Refill wand &
6 ft. suction hose, cam lock
fittings and panel cap
Panel Check Valve Pump/Motor Assembly
Strainer
40 Mesh
(P/N 3350-0144)

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Installation and Operation Manual
Because of the potential differences in fire
apparatus plumbing and foam system configuration, it
is not practical to depict exactly how each Power-Fill
FoamPro unit will be installed on a particular
apparatus. Most of the information contained in the
following sections will apply to most situations.
Read these sections thoroughly. Plan and
design where and how to install this equipment
in the apparatus before beginning the actual
installation. The following diagrams provide guide-
lines for the location of the system components.
Determine the locations of the components to be
installed, such as foam tanks, foam refill pump/motor
assembly, refill control panel, outboard pickup panel
and placard. Try to place components in locations
that will allow the least amount of hose and fittings.
Locate the foam pump/motor assembly (DC version
only) in an area that is protected from road debris
and excessive heat buildup. The foam pump/motor
assembly should be located as close to the outboard
pickup and placard as possible. Locate the outboard
pickup and placard low on the control panel with the
control module close by.
5 Plan Ahead
Foam Tank
Foam Pump/Motor Assembly
Panel
Controller
Panel Pickup Assembly

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Installation and Operation Manual
Power-Fill System
The system schematic on the following pages
show the plumbing for both the DC truck-mounted
system and the AC portable unit.
Mount the motor and pump horizontally.
If strainers are installed, make sure they are
located in an accessible location as they will
require regular maintenance.
Suction hose to be rated for a minimum of
23 inches (584mm) Hg vacuum and 50 psi
(3 BAR) working pressure.
All other hoses are to be rated for 50 psi (3 BAR).
Use the supplied plastic 1” hose barbs with the
flow switch. Do not mount the flow switch directly
to the pump or other rigid device. Provide proper
strain relief so that the flow switch is not supporting
the hose weight. Do not mount the flow switch near
the exhaust manifold or where it will be exposed to
temperatures above 210°F.
All fittings are to be compatible with chemicals
being pumped.
Install independent drains in lines that may cause
damage if frozen.
Plumb the fill line to the lowest part of the tank and
parallel to the bottom of the tank. This will eliminate
cavitation in the outlet of the tank and will minimize
foaming of the chemical.
Do not plumb refill discharge line directly into the
FoamPro foam system inlet line.
6 Plumbing the System
DC Truck-Mounted System AC Portable System
Foam Tank
To Foam
System
Strainer
(Optional)
Pump/Motor
Assy.
Check Valve
Foam Bucket or
Outside Source
Panel
Connection
Selector Valve
Foam Tank
To Tank
To Foam
System
Strainer
(Optional)
Flow
Switch
Independent Drain
Line required in this
line
Pump/Motor Assy.
Independent Drain Line
required in this line
Check Valve
Foam Bucket or
Outside Source
Panel
Connection
From
PumpCheck
Valve
To Drain
Flush
Drain

A Safe Fleet Brand
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Installation and Operation Manual
The schematic on pages 9 and 10 show how to wire the
electrical components for both the DC truck-mounted
system and the AC portable system.
Some things to keep in mind:
Do not hook up main power until all connections
have been made and are tight.
Use the recommended wire gauge specified
or larger.
The system can only perform when electrical
connections are sound, so make sure each one
is correct and tight.
Do not mount radio transmitter or transmitter cables
in direct or close contact with the system wiring.
CAUTION: Always disconnect the power and
ground connections before electric arc welding at
any point on the apparatus. Failure to do so will
cause damage to electrical components.
Use of standard automotive wire of the size specified
on the schematic that is grease and fuel resistant is
recommended.
CAUTION: Low battery voltage or voltage drop may
cause the system to malfunction. Provide power
from a master switch terminal. Accessories, such as
pump primers and lights, may cause voltage drops
when activated. Do not place such accessories on
the same circuit.
FOAM TANK LEVEL SENSOR
A foam tank level sensor must be mounted into the top
of the foam tank to monitor full concentrate condition.
A side-mount tank level sensor is supplied with the
system. If this sensor cannot be used in the apparatus
being built, a top/bottom mount sensor is available
(p/n 2510-0028).
The side-mount tank level sensor has 1/2-inch NPT
threads and must be installed as close to the top of
the foam tank as possible. After installation, the sensor
must be sealed with a suitable sealant to prevent
concentration leakage. Check the side-mount sensor
with a powered test light. With no or low level of
chemical in the tank, the test light should be off. With a
full tank, the light should be on. If the light does not come
on when the tank is full, reposition the sensor until the
light illuminates. Reseal the switch to prevent leakage.
A top/bottom mount sensor is available. The sensor has
1/8-inch NPT threads. Mount the sensor in the top of the
foam tank in a vertical position. Use suitable sealant to
prevent concentrate leakage. There must be room above
the tank to route the cable back to the control unit.
Check the tank level sensor with a powered test light.
With no foam in the tank, the switch contacts should
be open and the test light should be off. If this is not
the case, remove the clip from the end of the low-level
sensor. Remove the float and reinstall 180° out of
position.
NOTE: Failure to install low-level switches will void
the FoamPro warranty.
7 Electronic Component Installation
and Hook-Up
Top Mount
(Optional)
Bottom Mount
(Optional)
Side-Mount
Tank Sensor
(Standard)

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Installation and Operation Manual
Power-Fill System
Provide adequate electrical power (41 amps @13.5V DC, 21 amps @ 27V DC) from the battery. Use 8
AWG wire directly from the battery or battery switch. Long wire runs will require a larger gauge wire for
proper operation. Use the following as guidelines for longer wire runs.
Electrical devices can be easily damaged by a weak or erratic power supply. The Power-Fill system is no
different - the better the power supply, the better the system will perform.
DO NOT connect the main power to leads that supply power to some other device, such as a light bar,
siren, or primer pump. Do not attach the red power wire to the hot side of the solenoid. Power and
ground for the controller needs to come from a separate power source.
NOTE: Any system without a flow switch will require Jumper 2520-0118 or system will shut down
automatically after 20 seconds.
Wire Size Wire Length
8 AWG 10 feet or less
6 AWG 10-20 feet
4 AWG 20 feet or more
DC Truck-Mounted System
Battery
Control Panel
Male Connector
with Female Pins
Female Connector
with Male Pins
Black
Red
Flow Switch
Float Switch
14 AWG 8 AWG
14 AWG
Brown
Battery
Power Solenoid
Pump/Motor Assy.
Negative Motor Lead
8 Ga Wire
Positive Motor Lead
8 Ga Wire
Three Pin
Connector
To ground or
negative side
of battery
Green wires
Blue wires
Do not attach the red
power wire to the hot
side of the solenoid.
Power and ground for
the controller needs to
come from a separate
power source.

A Safe Fleet Brand
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Installation and Operation Manual
AC Portable System
The model 3435-1020 Power-Fill AC system requires a 120 VAC standard power source with 15 amp circuit
protection. The model 3435-1021 Power-Fill AC system requires a 240 VAC standard power source with 10 amp
circuit protection. A ground fault interrupter is attached to the cord for safety. DO NOT remove the GFI from the cord
or operate the system without a GFI in the line. The tank level indicator on the panel requires 12 V DC power from
the battery or master switch. This line can be wired with 14 AWG automotive-type hookup wire.
DO NOT remove GFI from power cord.
The use of an excessively long extension cord is not recommended and will affect the performance of the system
If the power cord becomes frayed or damaged, replace the entire cord.
Unplug the main power source when unit is not in use.
Tank Level
Indicator
Power ON/OFF Switch 120 VAC Power 15A
(240 VAC Power 10A–Not Shown)
Battery
14 AWG
GFI
Level Sensor