Safe Fleet FoamPRO AccuMax 3020 User manual

1
INSTALLATION AND
OPERATION MANUAL
AccuMax
Single-Point Injection Systems
Models 3020/3040/3060/3090/3150/3300
Form 903
Rev. 8/19
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]

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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.......................................................... 5
3 SYSTEM COMPONENT DESCRIPTION......................................................................... 7
4 INSTALLER SUPPLIED PARTS ...................................................................................... 9
5 INSTALLATION PLANNING ........................................................................................... 12
6 FOAM PUMP & HYDRAULIC CONTROL VALVE INSTALLATION................................ 13
7 HYDRAULIC PLUMBING INSTALLATION ..................................................................... 14
8 WATER AND FOAM PLUMBING COMPONENT INSTALLATION................................. 16
9 ELECTRICAL EQUIPMENT INSTALLATION ................................................................. 21
10 MAKE SURE EVERYTHING IS WORKING RIGHT........................................................ 29
11 CALIBRATION AND SETUP........................................................................................... 32
12 OPERATION INSTRUCTIONS ....................................................................................... 35
13 MAINTENANCE .............................................................................................................. 42
14 TROUBLESHOOTING .................................................................................................... 43
15 SPECIFICATIONS .......................................................................................................... 48
16 WARRANTY..................................................................................................... Back Cover
Installation and Operation Manual
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. 903.

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Installation and Operation Manual
1Safety Before attempting to install a FoamPro AccuMax System, read all
of the following safety precautions and follow carefully.
Installation and Operation Manual
The following special notices are used to notify and advise
the user of this product about procedures that may be
dangerous to the user, or result in damage to the product.
NOTE: Notes are used to notify of installation,
operation, or maintenance information that is
important but not safety related.
CAUTION: Caution is used to indicate the presence
of a hazard, which will or can cause minor injury or
property damage if the notice is ignored.
WARNING: 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: 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.
• Do not pump at pressures higher than the maximum
recommended pressure. [300 PSI (20.7 BAR)]
• Do not permanently remove or alter any guarding
devices or attempt to operate the system when
those guards are temporarily removed.
• Always disconnect the power source before
attempting to service any part of the pump.
• Release all pressure within the system before
servicing any of its component parts. Slowly
loosen the foam pressure line fittings and allow the
pressure to escape. Protect face and eyes from any
potential spray which may occur.
• Drain all concentrate and water from the discharge
system before servicing any of its component parts.
• Check all hoses for weak or worn conditions after
each use. Ensure that all connections and fittings
are tight and secure.
• Use only pipe, hose, and fittings from the foam
pump outlet to the injection point, which are rated
at or above 400 PSI (28 BAR) minimum rating, at
which the water pump system operates.
• Use only pipe, hose, and fittings from the hydraulic
oil pump to the foam pump hydraulic motor, which
are rated at least the maximum hydraulic pressure
rating of the system shown in Section 15 or better
and are approved for mobile hydraulic system use.
• Any electrical system has the potential to cause
sparks during service. Take care to eliminate
explosive or hazardous environments during
service/repair.
• Rotating drive line components can cause injury. Be
careful of rotating components when adjusting load
sense pump compensator.
CAUTION: Do not attempt to operate the system at
or above a temperature of 160ºF (71ºC).
WARNING: Ensure that the electrical source of
power for the unit is a 12 or 24 Volt, negative ground
DC system. Power and ground lines must come
directly from the battery without any connections to
other high power devices, such as primer pumps,
hose reels, light bars, etc. Power required for the
valve driver box on the hydraulic motor-driven foam
pump must have a minimum current rating of at
least 5 AMPS.
CAUTION: Periodically inspect the pump and the
system components. Perform routine preventive
maintenance as required. Failure to perform routine
maintenance may cause damage to the system.
See the maintenance section of this manual for
recommended maintenance procedures and
intervals between maintenance work.
NOTE: Read and understand these installation
instructions before proceeding with the
equipment installation.
CAUTION: Use only approved petroleum-based
hydraulic fluids meeting the specifications as
noted in Section 4. Never mix fluid types. Ensure
all hoses and seals are compatible with fluids used.
Do not use water or glycol-based fluids. Do not use
phosphate ester-type fluids.
CAUTION: Dirt and contaminants are the
primary causes of premature wear and failure in
any hydraulic system. Use extreme care during
assembly and service to keep contaminants out of
the system.
AccuMax SP

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Installation and Operation ManualInstallation and Operation Manual
WARNING: Always disconnect the ground straps,
electrical wires and control cables from the Digital
Display Control Module and all other FoamPro
equipment before electric arc welding at any point
on the apparatus. Failure to do so will result in
a power surge through the unit that could cause
irreparable damage.
CAUTION: All DOT, SAE or other applicable standards
must be followed when installing the hydraulic
supply system. Pay close attention to engine and
transmission manufacturer drive limitations.
CAUTION: Never attempt to cut or lengthen the
molded cables. Doing so will result in RFI/EMI
interference. Contact the factory if molded cables of
a different length are required.
CAUTION: To ensure the integrity of fitting
connections in the hydraulic system, use only SAE
JIC 37° flare or equal-type hose connections.
CAUTION: The cables shipped with each FoamPro
system are tested at the factory with that unit.
Improper handling and forcing connections can
damage these cables which could result in other
system damage.
CAUTION: The foam tank low-level sensor must be
utilized to protect the foam pump from dry running.
Failure to do so will void warranty.
CAUTION: When pouring foam concentrate directly
into the foam pump the inlet strainer is bypassed.
Make sure contaminants are not poured into pump
chamber. Premature pump wear or damage may result
if contaminants are allowed to enter pump chamber.
CAUTION: Do not run the FoamPro system for more
than one minute deadheaded against the pressure
gauge as the foam pump could be damaged.
CAUTION: When operating the FoamPro in the
“Simulated Mode” function, an outlet for the
foam concentrate must be provided. Otherwise
dangerous excessive pressure may be built up in
the apparatus water piping and/or hoses. This outlet
for the foam concentrate can be provided by turning
the ‘CAL/INJECT’ valve to the ‘CAL’ position.

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Installation and Operation Manual
AccuMax SP
2 A Quick Look at How the System Works
Installation and Operation Manual
The FoamPro AccuMax Single-Point system is
an electronically-controlled, hydraulically-driven,
foam concentrate proportioning system designed to
provide the wide range of foam concentrate injection
rates necessary for both Class A and Class B foam
operations.
The FoamPro system will accurately deliver from 0.1%
to 10.0% foam concentrate to the foam injection point.
The maximum rated concentrate flow rates obtainable
are shown in the system specifications in Section 15.
The FoamPro AccuMax SP system is a flow-based
proportioning system that measures water flow and then
injects the correct proportional amount of foam concentrate
to maintain the desired percentage. The basic FoamPro
system is shown in Figure 2-1. The flowmeter measures
the water flow and sends a signal to the Digital Display
Control Module. Another flowmeter in the foam discharge
line of the foam pump monitors the foam pump output.
Constant comparison of these two information signals
by the computer ensures maintenance of the desired
proportion of foam concentrate at all times based on
water flow rate, independent of any variations in fire pump
intake or discharge pressures. As water flow increases
or decreases the foam concentrate rate of injection is
increased or decreased automatically to correspond to
water flow, maintaining the proper concentrate percentage
as selected on the Digital Display Control Module.
Foam concentrate is injected directly into the water
stream on the discharge side of the water pump. It is
then fed as foam solution into a standard fog nozzle,
an air-aspirated nozzle, a straight bore nozzle, or into a
CAFS system, by the main fire pump.
Since the foam is injected on the discharge side of the
fire pump, and check valves are used at installation,
contamination of the booster tank, fire pump, and relief
valve with foam concentrate is eliminated.
Hydraulic power to operate the foam pump is to be
provided by a separate hydraulic pump driven by the
apparatus system. Electrical power to operate the foam
systems is provided by the apparatus electrical system.
Order optional system components listed in Section 3
to accommodate system design and requirements. The
components listed have been tested with the FoamPro
systems and provide for optimum system performance.

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Installation and Operation Manual
Hydraulic Pump
and ground
Hydraulic Control Driver
Figure 2-1 FoamPro 3000 System Layout
Installation and Operation Manual

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Installation and Operation Manual
AccuMax SP
3 System Component Description
14
3
2
8
7
6
5
14
13
12
11
10
15
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Installation and Operation Manual
The following components are packaged with the
standard FoamPro AccuMax SP system:
1. Digital Display Control Module
2. Molded Cables
3. Foam Pump Assembly
4. Instruction Placard
5. Low-Tank Level Sensor (One required. Not
packaged with the unit. Order separately.)
6. Hydraulic Control Driver
7. Calibrate/Inject Valve
8. Inlet Line Strainer
9. Check Valve NPT Foam Injection This NFPA
1906 (draft) required check valve prevents water
back flowing into foam system.
10. RFI/EMI Suppression Beads
11. FoamPro Paddlewheel Flowmeter (The flowmeter
is a required component. The size is specified and
ordered under a separate part number when the
FoamPro system is ordered. The flowmeters are
available with 1-1/2, 2, 2-1/2, 3, and 4-inch NPT
threads. All flowmeters have grooved victaulic ends.
Part numbers for the various flowmeters can be
found in Section 15. Up to four flowmeter sensors
can be used with the FoamPro System when a
MultiFlo interface is used.)
12. Hydraulic Pump
13. Foam Flowmeter
14. Hydraulic Pump Suction Filter
(3020 & 3040 Systems Only)
15. Foam Pump Relief Valve

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Installation and Operation Manual
System Accessories Available
Remote Start/Stop (12 volt DC only)
Part Number 3435-0155
FoamPro MultiFlo Interface
The basic system requires at least one flowmeter
to sense water flow in the discharge piping. The
FoamPro MultiFlo Interface allows a total of four
flowmeters to be used. The display will show the
discharge flow on the selected flowmeter.
Part Number 2527-0140
System Placard
Part Number 6032-0015
Low-Tank Level Sensor
Vertical Mount
(P/N 2510-0028)
Side Mount
(P/N 2510-0032)
Solid State Contactor
Part Number 2510-0043
Manual Override
Part Number 3430-0764
System Specification Placards
System Part Number
3020 6032-0028
3040 6032-0030
3060 6032-0032
3090 6032-0070
3150 6032-0048
3300 6032-0073
Installation and Operation Manual
Foam Flowmeter
Ball Valve
To Cal/Inj. Valve to Container
Pressure Gauge
AccuMax Calibration Kit
Part Number 3430-0831
Nesconset, NY 11767 USA
Size/ Thread All Stainless Steel
1-1/2" NPT P/N 3320-1001
2" NPT P/N 3320-1002
2-1/2" NPT P/N 3320-1003
3" NPT P/N 3320-1004
4" NPT P/N 3320-1005
Main Waterway Check Valve with Drain Port

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Installation and Operation Manual
AccuMax SP
4 Installer Supplied Parts
Installation and Operation Manual
FoamPro AccuMax SP systems are provided with
major components and accessories required for
installation. Due to differences in chassis and apparatus
configurations, the installer must provide, hydraulic
coolers, fluids, reservoir, pipe, hoses, tubing, wire and
fittings to satisfy installation requirements. The following
paragraphs list the specifications for selection of these
components. Before beginning system installation,
read this section thoroughly to make sure the proper
components are selected. For detailed system
installation instructions, refer to Sections 5, 6, 7, 8 and 9.
CAUTION: All DOT, SAE or other applicable
standards must be followed when installing the
hydraulic system. Pay close attention to engine and
transmission manufacturer drive limitations.
Hydraulic Pump Drive Selection
The foam pump for the FoamPro AccuMax SP system
is powered by hydraulics. Power for the system comes
from hydraulic oil supplied by a hydraulic pump attached
to the apparatus engine. To obtain optimum performance
from the hydraulic motor-driven foam pump, FoamPro
has designed the system to use a variable displacement
piston hydraulic pump. The FoamPro hydraulic pump
provides proper hydraulic fluid flow with reduced heat
load, torque, and horsepower requirements.
The FoamPro hydraulic supply pump will provide
the correct fluid flow over the widest range of engine
speeds. See system specifications for the maximum
required pump speed to attain maximum performance
levels. By using a PTO ratio greater than 1.0, the
minimum engine speed for full system performance
could be idle speed.
A transmission PTO should be used to drive the hydraulic
supply pump. Transmission PTOs have greater torque
capabilities and provide adequate power for the hydraulic
pump. Selection of a PTO transmission with a standard
SAE mounting pad will allow bolting the hydraulic pump
directly to the transmission. The FoamPro hydraulic supply
pump has a standard SAE mounting flange and shaft. See
Section 15 for flange size and shaft configuration. Other
shaft configurations are available. The shaft rotation
of the pump is clockwise when looking at the pump
shaft, or counterclockwise when facing the rear of
the pump. Check with the FoamPro factory for other
configurations that may be available. See Section 15 for
pump dimensions.
Control of the PTO may be provided by a manual shift
lever, shift cable, or solenoid. The manual shift-type PTO
can be left in gear all the time to circulate oil as soon as
the engine is started since the hydraulic pump will draw
less than 5 hp when operating in standby mode. The PTO
shift can be labeled “Service Disconnect.”
When selecting a transmission PTO, it is imperative
that consideration be given to frame clearances and
the space in which the hydraulic supply pump is to
be mounted. For new installations, initial design and
planning will eliminate clearance problems. When the
FoamPro AccuMax SP system is being installed as
a retrofit, all clearances must be taken into account.
Consult PTO and chassis manufacturers to determine
dimensions and clearances required.
CAUTION: The use of an accessory drive pad is
not recommended since adequate torque usually
is not available to drive the hydraulic supply pump
and accessories.
Oil Reservoir
A hydraulic reservoir will be required to be installed
in the apparatus. See Section 15 for minimum
recommended reservoir capacity. A larger reservoir may
be installed and is recommended if the apparatus is to
run at maximum capacity for an extended period of time
and to allow air to settle out of the oil.
The reservoir must have a diffuser on the inlet
to prevent entrapment of air into the system. A
particle screen, of 100-170 mesh, on the oil outlet is
recommended to help keep dirt out of the system. A
baffle to separate the inlet and outlet sections should be
installed in the reservoir. A vented, filtered breather of
sufficient size to allow filling of oil is required and an oil
drain plug is recommended.
A sight gauge with thermometer is also recommended
for easy checking of the oil level and to monitor oil
temperature.
The oil reservoir should be mounted away from heat
sources, such as exhaust systems, and be in a location
that allows easy access for checking and filling the oil.

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Installation and Operation Manual
Oil Cooler
An oil cooler capable of maintaining the temperature
of the hydraulic oil at 140° to 180°F (60° to 82°C) is
required. Use of an air-to-oil radiator-type heat
exchanger mounted in front of the apparatus radiator
should provide adequate cooling for the hydraulic system
oil. An electric fan attached to the oil cooler permits
mounting of the oil cooler anywhere fresh air circulation
is available. A thermostat is required to be included for
quick warm-up of the oil in cold climates. Check the
system specifications page in Section 15 for minimum
heat load information to properly size the cooler.
Oil-to-water heat exchangers can be installed, but
they present special problems such as sediment
accumulation, drainage and overheating when running in
standby mode for extended periods without discharging
water. If a hydraulic oil-to-water heat exchanger
is to be used, proper maintenance, monitoring, and
pumping procedures must be followed. The oil-to-water
exchangers must be installed per the manufacturer’s
recommendations and NFPA requirements.
Hydraulic Oil
Ratings and data for the FoamPro AccuMax systems
are based on operating with premium hydraulic fluids
containing oxidation, rust, and foam inhibitors. These
premium fluids include premium turbine oils, API CD
engine oils per SAE J183, M2C33F or G automatic
transmission fluids (ATF), Dexron II (ATF) meeting
Allison C-3 or Caterpillar TO-2 requirements
The recommended hydraulic fluid operating viscosities
are typically 70 to 278 SUS (12 to 60 cSt) within the
recommended temperature operating range for optimum
performance. The hydraulic oil should have an ISO rating
of between 32 to 68 depending on climatic conditions.
Hydraulic Hoses and Fittings
High pressure hydraulic hoses and fittings are to be rated
at least at the maximum working pressure of the system.
To reduce the potential for leaks at the hydraulic fittings,
use SAE 37° flare JIC-type fittings or SAE straight thread
O-ring fittings. See the table for required fitting sizes,
minimum hose size, and minimum hose pressure ratings
for the hydraulic components in Section 15.
Foam Concentrate Suction Lines
Fittings and hoses from the foam tank to the inlet of the
foam pump must be supplied. Use the minimum inside
diameter or larger clear suction hose shown below for the
corresponding system depending on the viscosity of the
foam concentrate. Many class B foams are more viscous
and will require one size larger inside diameter hoses.
Model Min. Hose ID
3020/3040 1-1/2"
3060 2"
3090 2-1/2"
3150 3"
3300 4"
Use fittings and components that are rated for 23” Hg
(584.2mm) vacuum and 50 PSI (3 BAR) pressure or
better. The components used must be compatible with
the foam concentrates used. Fittings used must be
made of brass or 300 series stainless steel. If a flushing
system is to be used, the pressure rating of those
components subjected to main water pump pressure
are to be rated to 400 PSI (28 BAR) or better.
A drain/air bleed valve should be provided to allow
draining of the tank and easier priming of the foam pump.
Foam Concentrate Discharge Lines
Fittings and hoses from the discharge of the foam pump
to the foam injection point must be supplied by the
installer. Hoses and fittings are to be 3/4” (19mm) for
the 3020 and 3040; 1” (25.4mm) for the 3060; 1-1/4”
(31.8 mm) minimum for the 3090; 1-1/2” (38.1mm) for
the 3150; and 2” (50.8mm) for the 3300 systems inside
diameter, rated at or above 400 PSI (28 BAR) working
pressure. Fittings and hoses must be compatible with all
foam agents to be used with the system. Use fittings of
brass or 300 series stainless steel.
WARNING: Do not use air brake tubing for foam
systems as the tubing is not compatible with most
foam concentrates.
The foam flowmeter supplied with the system is to be
installed in the foam concentrate discharge line of the
foam pump. This requires a straight length of brass or
300 series stainless steel pipe 10" (254mm) minimum
before and 5" (127mm) minimum after the flowmeter.
This ensures laminar flow through the flowmeter. Failure
to comply with these minimum dimensions will affect the
accuracy of the entire foam system.
Foam Concentrate Tank(s)
Foam concentrate tanks must be supplied to suit the
capacity required for the apparatus application. The
tank(s) should meet NFPA minimum standards for the
design capacity, including filler size, vapor pressure
venting, and drain facilities.
Installation and Operation Manual

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Installation and Operation Manual
AccuMax SP
Installation and Operation Manual
Check Valves
It is required by NFPA to install a check valve in the foam
concentrate injection line to prevent foam concentrate
flow from the foam tank to the injection point (at the main
waterway) due to static head pressure. The concentrate
check valve is included with each system (3/4" NPT with
the 3020 and 3040; 1" NPT with the 3060; 1-1/4"’ NPT
with the 3090; 1-1/2" NPT for the 3150; 2" NPT for the
3300; and a 1/2"’ NPT with the “D” sections).
If the system is to be installed in an apparatus where
potable water sources may need to be isolated from
the possibility of foam contamination, there are a few
methods that can be incorporated into the design of the
apparatus or on the outside of the apparatus.
One of the methods is to install check valves in all
water line locations, such as flush lines, where foam
concentrate could drain back into the water pumps or
tanks of the fire apparatus, and where the water piping
that will supply foam solution connects to the apparatus
water pump discharge.
Another method is to install a check valve or other device
between the water pump tank and the suction inlets to
the water pump, or outlets of the hydrant.
These are just a few of the methods that may be available.
Drain lines must be provided from all water and foam
solution piping components to prevent freezing in cold
weather. Multiple drain systems that allow individual
drain lines to connect with one another may allow foam
or water to circumvent the check valves. Care must be
taken to avoid this possibility as contamination of the
water tank, foam tank, or water pump may result.
Electrical Requirements
Electrical power and wiring must be supplied from the
main apparatus electrical system to the AccuMax SP
system. The power must be supplied directly from the
battery without any connections to other high power
devices, such as primer pumps, hose reels, light bars,
et., with its own disconnect switch or a switch or contactor
actuated by the battery disconnect switch, PTO switch or
other device.
The system can be operated with either a 12 VDC or 24
VDC, negative ground, power source. The system should
be protected with a 10 AMP fuse for 12 VDC systems and
5 AMP fuse for 24 VDC systems. All system components
should all be powered from the same terminal and ground
connections should all be common. Use a standard
14 AWG automotive hookup wire.
NOTE: See "POWER SUPPLY" (page 27) in the
Electrical Installation Section for important installation
information.
CAUTION: Always disconnect the ground straps,
electrical wires, and control cables from the Digital
Display Control Module, the control driver box, and
any other FoamPro equipment before electric arc
welding at any point on the apparatus. Failure to
do so will result in a power surge through the unit
causing irreparable damage and is not covered
under warranty.

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Installation and Operation Manual
5 Installation Planning
Installation and Operation Manual
Because of the potential differences in apparatus
plumbing and foam system configuration, it is not
practical to depict exactly how each FoamPro unit can
best be installed onto a particular apparatus. Most of the
information contained in the following sections, however,
will apply to any situation.
NOTE: It is recommended that you read the
following sections thoroughly before beginning
installation of the FoamPro AccuMax SP system. 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 locations of the components to be
installed such as foam tank(s), foam pump, oil reservoir,
oil cooler, foam strainers, tank valves, flowmeter(s) and
hydraulic pump. Try to place components in locations
that require the least amount of hoses and fittings.
Locate the FoamPro system components in an area
that is protected from road debris and excessive heat
buildup. Since the master power switch and CAL/
INJECT valve are components you may need to access,
it is recommended that they be installed in an accessible
location in the vicinity of the operator’s panel.
The foam pump unit must be mounted below the discharge
of the foam tank(s) to provide for gravity feed to the foam
pump. Locate the foam tank(s) where the refilling can be
easily done with 5 gallon (19 liter) pails and other methods
suitable to the end user. Most water tank manufacturers
will build foam tanks into the booster tank. When specifying
integral foam tank(s), make sure provisions are made for
installation of the low-tank level sensor as well as foam
suction connections and tank drainage.
Determine a location on the operator panel of the
apparatus for the Digital Display Control Module.
Consideration must be given for routing the control
cable from the Digital Display Control Module to the
hydraulic control valve and the main waterway flow
meters. If necessary, order longer or shorter cable
assemblies to suit the location demands.
CAUTION: Never attempt to cut or lengthen the
molded cables. Doing so will result in RFI/EMI
interference. Contact the factory if molded cables of
a different length are required.
High viscosity foam concentrates (2000 centipoise and
higher) or inlet lines longer than 10 feet, will require
the foam intake to be one size larger. When larger inlet
piping is used, a larger foam strainer is required to
reduce the pressure drop.
Like any hydraulic system, the FoamPro AccuMax
SP will require cooling and hydraulic fluid filtration.
An oil cooler must be provided for the system and
consideration must be given to the location. The cooler
must be mounted in an area where adequate cool
air can flow over the cooler fins. The ideal location
for an oil cooler is in front of the apparatus engine
radiator. Consult the chassis manufacturer to ensure
adequate fan capacity is available to provide the proper
air flow. Fluid filtration is vital to a hydraulic system. A
suction strainer in the reservoir is required. A filter is
provided on the hydraulic pumps on the 3060 thru the
3300 systems. The 3020 and 3040 systems require a
separate suction filter as supplied.
When planning the installation, consideration must also
be given to the hydraulic supply pump location, drive
configuration and hose routing.

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Installation and Operation Manual
Installation and Operation Manual
AccuMax SP
6 Foam Pump and Hydraulic Control Valve Installation
Installation and Operation Manual
Hydraulic-Driven Foam Pump Assembly
The AccuMax systems are designed to be used with
various gear type foam pumps currently in use in the
industry. The standard foam pump used in the systems
are manufactured by Fire Lion. Optional approved
gear type foam pumps designed into the system are
manufactured by Aurora (Edwards) and Trident (Titan).
Specifications for these options can be found in
Section 15.
The foam pump assembly must be mounted in a
horizontal position. The base of the foam pump must
be anchored to a surface or structure that is rigid and
of adequate strength to withstand the vibration and
stresses of apparatus operation. Mounting dimensions
for the FoamPro AccuMax SP foam pump and motor
assemblies can be found in Section 15.
CAUTION: Flexible hose connections are required
between the major FoamPro components and the
main water system. Do not hard plumb the system.
Be sure the hydraulic hoses and the foam concentrate
hoses can be properly routed to the inlets and outlets
on the foam pump. Foam concentrate must gravity feed
to the foam pump inlet from the foam tank(s). The foam
pump must be mounted in an area to avoid excessive
exhaust system heat buildup.
Protection must be provided for the hoses and wiring
to prevent chafing and abrasion during operation of
the foam system. Protect the foam pump base from
excessive road spray and debris. Although the system
is sealed and designed to be resistant to the harsh
environment of fire fighting apparatus, a protected
location with easy operator access is the recommended
installation location.
Choosing the Proper PTO
It is important to turn the hydraulic pump at the proper
speed to ensure that the correct hydraulic pressure is
produced over the full operating range of the foam system.
When selecting a PTO to drive the hydraulic pump,
compare the maximum RPM for the water pump with the
maximum RPM (3,600 RPM) for the hydraulic pump. Then
select a PTO that will provide the best performance at a
lower RPM.
For Example: the maximum speed you can turn the water
pump is 1,800 RPM. For the 3150 system hydraulic pump,
the minimum speed is 1,375 RPM, and the maximum
speed is 3,600 RPM. It is recommended to choose a PTO
with a range of 1 - 1.60 conversion rate (or higher).
According to this example, the following table shows
the Engine Speed with the corresponding Hydraulic
Pump Speed:
Engine Speed Hydraulic Speed
800 RPM 1280 RPM
900 RPM 1440 RPM
1000 RPM 1600 RPM
1100 RPM 1760 RPM
1200 RPM 1920 RPM
1300 RPM 2080 RPM
1400 RPM 2240 RPM
1500 RPM 2400 RPM
1600 RPM 2560 RPM
1700 RPM 2720 RPM
1800 RPM 2880 RPM

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Installation and Operation ManualInstallation and Operation Manual
7 Hydraulic Plumbing Installation
Figure 7-1 FoamPro AccuMax SP Hydraulic System Diagram
Hydraulic
Reservoir
Hydraulic
Pump Suction
Hydraulic Pump
Cooler Inlet
Motor Inlet
Motor Return
System Return
Hydraulic
Oil Cooler
Foam Pump/
Motor
Assembly
Hydraulic Motor
Case Drain
Hydraulic Pump
Upper Case Drain
Hydraulic Pump
Bottom Case Drain
Figure 7-1 provides some recommended guidelines for
the location of the hydraulic system components. When
making hydraulic component connections ensure all
applicable DOT and SAE standards are followed. Use
hoses and fittings rated at least the maximum working
pressure listed in Section 15 for the hydraulic oil high
pressure lines. See Section 15 for required fitting sizes,
minimum hose size, and minimum pressure ratings.
The fittings required to connect the hydraulic hoses
to the FoamPro AccuMax SP foam pump motor and
hydraulic supply pump are SAE ORB (O-Ring Boss)
fittings with SAE JIC 37° flare swivel, and SAE Split
Flange port connections.
CAUTION: To ensure the integrity of fitting
connections in the hydraulic system, use only SAE
JIC 37° flare, SAE O-Ring Boss, or SAE Split Flange-
type hose connections.
CAUTION: Use only approved petroleum-based
hydraulic fluids as described in Section 4. Never
mix fluid types. Ensure all hoses and seals are
compatible with fluids used. Do not use water or
glycol-based fluids. Do not use phosphate ester-
type fluids. Other hydraulic fluids such as SAE
10W-40HD motor oil are too viscous for proper
pump performance.
Hydraulic Power Source
The hydraulic power for the FoamPro AccuMax SP
system is supplied by a hydraulic pump mounted on the
fire apparatus engine, transmission, or auxiliary PTO.
The hydraulic pump supplied with the system has been
chosen to provide the required flow and pressure to
drive the FoamPro system.
Refer to Section 4 of this manual for further pump and
PTO information and Section 15 for detail dimensions
of the pump. See the table in Section 15 for all proper
hose sizes, pressure ratings, and fittings for the various
hydraulic components supplied by FoamPro.

15
Installation and Operation Manual
AccuMax SP
Installation and Operation Manual
Figure 7-2 Oil Cooler Hose Connections
Figure 7-3
Hydraulic Supply Pump Connection Ports
Oil To
Reservoir
Oil
Cooler
Oil From
Hydraulic
Valve Block
Thermostat
Control
Valve
Electric
Fan
Pump B to Motor
See Section 15 for port sizes and ratings
Port S
Charge
Pump Inlet Port A
Motor Return
Case Drain Port
Use Lowest Case Drain
as Inlet from Motor
Case Drain Port
Use Uppermost Case
Drain as Outlet to
Reservoir
Hydraulic Reservoir
The hydraulic reservoir for the system is to conform
to the description in Section 4 and to all SAE and
DOT standards. See table in Section 15 for minimum
reservoir capacity for the unit being installed.
Hydraulic Oil Filtration
Hydraulic fluid filtration is vital to the performance and
life of any hydraulic system. The AccuMax systems are
no different. A suction strainer of at least 100 to 170
mesh is required in the outlet of the reservoir and should
be sized to accommodate the charge pump flow of the
system without significant pressure drop.
Models 3060 thru 3300 hydraulic pumps have a spin-
on filter already installed for that particular pump’s
protection. This filter has a Beta 10 rating of 10 to 20.
Models 3020 and 3040 systems require a suction filter
with a Beta 10 rating of 10 to 20. The flow rating on the
filter should be at least 25 gpm when used for suction. A
filter element is supplied with these systems.
CAUTION: Ensure all hydraulic hoses and
components are clean and free of debris.
CAUTION: Ensure hydraulic fluid is clean and free
from contamination when filling and changing the
fluid in the system.
Hydraulic Oil Cooler
An oil cooler is required in the hydraulic system to
ensure proper oil temperature for optimum performance
and to avoid damage to the hydraulic components.
The actual cooler size required will depend on the
system requirements, the location of the cooler, and
the manufacturer of the cooler. Typical oil-to-air cooler
connections are shown in Figure 7-2. The cooling
requirements for the system being installed are listed in
the table in Section 15.
If an oil-to-water exchanger is used, proper
maintenance, mounting, and operating procedures must
be maintained. A method to circulate cool fresh water
must be provided when the hydraulic pump is engaged.
A drain port must also be provided to prevent freezing
and to allow flushing.
Hydraulic Supply Pump Connections
After completion of the mounting of all hydraulic system
components, hose connections must be made. A table
in Section 15 shows the connector and minimum hose
sizes and Figure 7-3 shows the connection ports to use
for the hydraulic supply pump. Specific pump drawings
for each system are found in Section 15. Always use
the uppermost case drain port available.
Pump Adjustment
The supplied hydraulic pump does not require any
adjustment. The pump is adjusted to give you maximum
performance throughout the entire operating range and
has been tested with your system.

16
Installation and Operation ManualInstallation and Operation Manual
8 Water and Foam Plumbing
Component Installation
The following diagram (Figure 8-1) provides
recommended guidelines for the installation of
the system components that handle water, foam
concentrate and foam solution. Note that additional
options such as dual-tank system, multiple flowmeters,
etc., are covered by the individual manuals included
with those systems and consideration must be given to
potential interferences.
Hydraulic Pump
and ground
Hydraulic Control Driver
Figure 8-1 FoamPro AccuMax SP System Piping

17
Installation and Operation ManualInstallation and Operation Manual
CAUTION: Flexible hose connections are required
between the major FoamPro components and the
main water system. Do not hard plumb the system.
Foam Pump Suction
The inlet hose from the foam tank should be a minimum of
1-1/2” (38.1 mm) ID for the 3020 and 3040, 2” (50.8 mm)
ID for the 3060, 2-1/2" (63.5 mm) ID for the 3090, 3” (76.2
mm) ID for the 3150, and 4” (101.6 mm) ID for the 3300
and have adequate wall stiffness to withstand the vacuum
of the foam pump while it is running without collapsing
[23” Hg (584 mm HG)].
Foam Pump Discharge Relief Valve
NOTE: To prevent possible foam cell contamination,
if the system is plumbed with an off-board pickup
you must plumb the Discharge Relief Valve back
to the suction side of the foam pump as per the
instructions. The discharge relief valves on the outlet port
of the hydraulically-driven foam pump are preset at the
factory to ensure optimum performance of the FoamPro
AccuMax system. The bypass line from the hydraulically-
driven foam pump relief must return to either the foam
concentrate tank or a minimum of 5 feet from the inlet port
of the foam pump. This will lessen the aerating of the foam
in the event of an over-pressurization of the system.
Calibrate/Inject Valve
The calibrate/inject valve is supplied in the fitting kit and
is to be positioned as shown in Figure 8-1 in the system.
This valve must be accessible by the pump operator
during normal operations. The valve is a 3-way directional
control valve that selects where the output of the foam
system will go.
Check to make sure the valve is installed properly. Look
at the ports as you move the selector handle. The flow
should go from the center port to each of the end ports.
The hoses to and from the valve should be 3/4" (19 mm)
for the 3020 and 3040, 1” (25.4mm) for the 3060, 1-1/4"
(31.8mm) minimum for the 3090, 1-1/2" (38.1mm) for
the 3150, and 2" (50.8mm) for the 3300 systems inside
diameter, rated at or above 400 PSI (28 Bar) working
pressure. Fittings are to be the same size as above and
made of brass or stainless steel, with the same minimum
pressure rating as the hoses.
The hose(s) from the calibrate side of the valve(s) may
have a lower pressure rating since it is used for system
calibration only and is always vented to the atmosphere.
The hose(s) from this port must be long enough to reach
a container outside the apparatus and may be coiled for
storage when not in use.
Line Strainer
The line strainer(s) provided with the FoamPro AccuMax
SP system are sized properly for most applications. See
Section 4 for further information. The appropriate strainer
is to be installed on the inlet side of the foam pump. The
hose from the foam tank should have adequate wall
stiffness to withstand the vacuum of the foam pump while
it is running without collapsing [23" Hg (584 mm HG)].
CAUTION: If a pressurized water flush system is
incorporated, the plumbing exposed to this pressure
must be rated at or above the operating pressure or a
minimum of 400 PSI (28 BAR).
Main Waterway Flowmeters
The FoamPro AccuMax SP system is designed to accept
flow reading signals from the FoamPro paddlewheel-style
flowmeter.
Proper flowmeter sizing is critical to system accuracy.
Select a flowmeter size based on actual flows required,
not standard pipe sizes. Refer to the installation drawing in
Section 15 for proper flowmeter sizing.
The flowmeters require that the amount of turbulence in
the pipe being monitored is as low as possible. Excessive
turbulence produces unstable and inaccurate flow
readings. The following installation guidelines will help
attain the best readings and maintain accuracy of the
FoamPro system when using the FoamPro paddlewheel
flowmeter in a tee or in the FoamPro Manifold.
1. A minimum 5 times the pipe diameter of straight run
pipe without any fittings is necessary upstream of the
flowmeter. 10 times is better. The longer the straight
run, the lower the turbulence. The following are the
recommended straight run lengths for given pipe
sizes:
Pipe Recommended
Size Straight Run Pipe
1-1/2" (38 mm) 7-1/2 to 15" (191 to 381 mm)
2" (50 mm) 10 to 20" (254 to 508 mm)
2-1/2" (64 mm) 12-1/2 to 25" (317 to 635 mm)
3" (76 mm) 15 to 30" (381 to 762 mm)
4" (100 mm) 20 to 40" (511 to 1016 mm)
2. The downstream plumbing of the flowmeter is not as
critical, but straight runs without fittings help maintain
accurate flow readings.
3. Do not mount a flowmeter directly after or before
an elbow or valve. Valves create severe turbulence
when they are “gated down” as shown in Figure 8-2.
4. Try to mount the flowmeters in a position that is
accessible for routine inspection and maintenance.
AccuMax SP

18
Installation and Operation ManualInstallation and Operation Manual
Figure 8-2 Flowmeter Placement
Figure 8-3 Flowmeter Position Range
The FoamPro paddlewheel-style flowmeter fittings
are specially designed tees that make inspection and
maintenance of the flow sensor easy. The threads of
the tees are available in NPT with grooved victaulic
ends, or BSP with grooved victaulic ends. In horizontal
runs the tees should be mounted as close to upright as
possible within the range shown in Figure 8-3.
With the use of a MultiFlo interface, two to four
flowmeters may be monitored simultaneously. A single
injection point that will supply foam agent to all foam
discharge outlets is required. See Form 880, provided
with the MultiFlo System, for further information.
Foam Discharge Flowmeters
The foam flowmeters shipped with the unit are
designed to give maximum performance and accuracy
over the full range of operations for the system. The
foam flowmeters are to be mounted in a horizontal
position. A straight run of hard piping before and after
the flowmeter is required. The following chart specifies
the minimum straight run required:
Model Pipe Minimum Straight Run Pipe
Size Before After
Flowmeter Flowmeter
3020& 3040 3/4" 8-1/4"(210 mm) 4-1/8"(105mm)
3060 1" 8-1/4”(210 mm) 4-1/8"(105mm)
3090 1-1/4" 8-1/4”(210 mm) 4-1/8"(105mm)
3150 1-1/2" 10-1/4”(260 mm) 5-1/4"(133 mm)
3300 2" 10-1/4”(260 mm) 5-1/4"(133 mm)
Injection Point
The position of the injection point MUST be in a place
that is common to all discharges which require foam
capability. This position may be before or after the
main water flowmeter, but not within the straight run
distance required for the flowmeter as previously
described. A separate injection point is not possible
for each discharge. If multiple flowmeters are used, the
injection point must be installed before the flowmeters
at the inlet to their common manifold (See Figure 8-4).
Most foam concentrates by nature mix with water very
quickly, so each discharge from a manifold will receive
equal amounts of foam concentrate if the manifold
is properly designed and installed. A static mixer or
special mixing considerations may need to be designed
into the system, especially when using thicker foam
concentrates and those that may not readily mix
with water.
Figure 8-4 Injector Fitting Placement
for Multiple Discharge
Foam Concentrate Check Valves
Check valves are provided to prevent foam concentrate
flow from the concentrate tank through the injection
point and into the main waterway when the system is
not in use. This is a NFPA requirement. A check valve
of the proper size is supplied for the standard systems.
See Figure 8-1 for component placement. The
concentrate check valves have a minimum cracking
pressure of 4 PSI (0.1 BAR) and are pressure rated
to 400 PSI (28 BAR) minimum working pressure. It is
a good idea to inject foam concentrate at a horizontal
or higher angle to allow water and debris in the water
line to drain away from the check valve(s) as shown
in Figure 8-5. This will avoid sediment deposits or
formation of an ice plug in cold weather applications.
Injection
Point

19
Installation and Operation ManualInstallation and Operation Manual
Injector Above
Horizontal Plane
DO
DON'T
Injector Below
Horizontal Plane

Figure 8-5 Foam Injector Position
Main Waterway Check Valves
If the system is to be installed in an apparatus where
potable water sources may need to be isolated from
the possibility of foam contamination, there are a few
methods that can be incorporated into the design of the
apparatus or on the outside of the apparatus.
One of those methods is to install check valves in all
water line locations such as flush lines, where foam
concentrate could drain back into the water pumps or
tanks of the fire apparatus, and where the water piping
that will supply foam solution connects to the apparatus
water pump discharge.
Another method is to install a check valve or other
device between the water pump tank and the suction
inlets to the water pump, or outlets of the hydrant.
These are just a few of the methods that may be available.
CAUTION: The usage of check valves or other
means of isolation are not to be used as a
substitute for proper flushing of apparatus lines
after usage.
Flushing System
Depending on the corrosiveness of the foam
concentrates used, or when changing foam
concentrate types or manufacturers, a flushing
system must be installed. Generally all Class
B foam concentrates must be flushed from
the system after usage with fresh water. Most
Class A foam concentrates are less corrosive
and do not require flushing after each use.
See Figure 8-7 for a typical flushing system
plumbing schematic.
Figure 8-6
Recommended Midship Pump Installation
Main Waterway
Check Valve
Injection Port (Optional location
on other side of Flowmeter)
Flowmeter
Drain Port
Minimum length of nipple for
2-1/2’’ pipe is 12-1/2’’ (318 mm).
Refer to Table on Page 20 for
recommended nipple lengths for
different pipe sizes.
Figure 8-7
Foam Concentrate Flushing System Diagram
From Foam
Tank
Foam Strainer
Mounted On Foam
Pump Inlet
Check
Valve
Check
Valve
Flush Water
Shut-Off Valve
From
Fire
Pump
Pump
Suction
Line
Injector Above
Horizontal Plane
Injector Below
Horizontal Plane
DO
DON’T
AccuMax SP

20
Installation and Operation ManualInstallation and Operation Manual
Outboard Pickup Diagram
Outboard Pickup Line
Switch to disconnect
Level Sensor when in
Outboard
Full Ported
Shut-off Valve
Full Ported
Shut-off
Valve
Strainer
Foam
Tank Driver
Box
Foam
Pump
Assy.
Drain Lines
On apparatus with multiple drain lines, the drains
from the foam solution discharge line should not
be piped into a multi-drain system before the check
valves. The standard multi-drain system from most
manufacturers will allow cross talk between the
drain lines and the apparatus water tank, resulting
in contamination of the water tank with foam. A
separate drain system should be provided for the
foam solution piping to prevent contamination of the
water tank and fire pump.
Outboard Pickup
An outboard pickup may be adapted to the foam
pump inlet. The pickup should be positioned
between the foam tank shut-off valve and the foam
inlet line strainer. A tee the same size as the tank
to pump line may be placed in the suction line with
the side leg of the tee going to the outboard pickup
shut-off valve at the panel. A sealed quick connect-
type fitting may be mounted to the panel for easy
access. The outboard pickup line should not exceed
10 feet and the same line size and specifications as
the tank to pump line should be utilized. The shut-off
valves must be full ported valves and be air tight. A
switch must be provided to disengage the low level
sensor when using the outboard pickup. This switch
may be a separate panel mount or one that is tied
into the pickup valve actuator.
NOTE: The tank shut-off valve must be closed
before opening the outboard valve when
switching to the offboard pickup. The offboard
pickup valve must be closed before opening
the tank valve when switching to the foam
tank operation.