Safe Fleet FoamPRO 1600 System User manual

INSTALLATION AND
OPERATION MANUAL
System 1600 and 1601
Form 850
11/17
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]

2
Installation and Operation ManualInstallation and Operation Manual
1 SAFETY................................................................................................................. .....3
2 A QUICK LOOK AT HOW THE SYSTEM WORKS.................................................... 4
3 SYSTEM COMPONENT DESCRIPTION................................................................... 5
4 INSTALLER SUPPLIED PARTS ................................................................................ 7
5 INSTALLATION PLANNING....................................................................................... 8
6 PLUMBING COMPONENT INSTALLATION ............................................................. 9
7 ELECTRICAL EQUIPMENT INSTALLATION........................................................... 13
8 MAKING SURE EVERYTHING IS WORKING RIGHT............................................. 19
9 CALIBRATION AND SETUP ................................................................................... 20
10 OPERATING INSTRUCTIONS................................................................................. 21
11 OPERATION OPTIONS ........................................................................................... 23
12 MAINTENANCE........................................................................................................ 25
13 TROUBLESHOOTING.............................................................................................. 26
14 PARTS IDENTIFICATION ........................................................................................ 28
15 CONTROL MODULE TEMPLATE/INSTALLATION DRAWINGS ............................ 31
16 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. 850.
TABLE OF CONTENTS
PAGESECTION

3
Installation and Operation Manual
System 1600/1601
Installation and Operation Manual
1. Do not pump at pressures higher than
the maximum recommended pressure
[400 psi (28 BAR)].
2 . Do not permanently remove or alter any guarding
devices or attempt to operate the system when
these guards are temporarily removed.
3. Always disconnect the power source before
attempting to service any part of the pump. Note,
this system contains a capacitor which will hold a
charge for a time after the power is disconnected.
Take care to dissipate this charge, by connecting a
12 or 24-volt test lamp from the pump base to the
positive main power terminal.
4. Release all pressure within the system before
servicing any of its components.
5. Drain all concentrate and water from the
discharge system before servicing any of its
component parts.
6. Check all hoses for weak or worn conditions after
each use. Ensure that all connections and fittings
are tight and secure.
7. Use only pipe, hose, and fittings from the foam
pump outlet to the injector fitting, which are rated
at or above the maximum pressure [400 psi (28
BAR) minimum] rating at which the water pump
system operates.
8 . Any electrical system has the potential to cause
sparks during service. Take care to eliminate
explosive or hazardous environments during
service/repair.
9. CAUTION: Do not attempt to operate the system
at or above a temperature of 160°F (71°C).
10. 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,
scene lighting, etc. Refer to Section 7 for
detailed information.
11. CAUTION: Ensure that the electrical
source of power for the unit is the appropriate
12 or 24 volt, negative ground DC system, with
a minimum current rating of at least 32 amps for
12 VDC or 16 amps for 24 VDC System 1600’s.
12. 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 pump. See the maintenance
section of this manual for recommended
maintenance procedures and intervals between
maintenance work.
13. CAUTION: Read and understand “Operating
Instructions” section before attempting to
operate the unit.
14. CAUTION: Always disconnect the ground
straps and control cables from the control
module or 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 to the system components.
15. CAUTION: The cables shipped with each
FoamPro unit are tested at the factory. Improper
handling and forcing connections can damage
these cables which could result in other
system damage.
1 Safety Before attempting to install a FoamPro System 1600 and/or 1601,
read all of the following safety precautions and follow carefully.

4
Installation and Operation ManualInstallation and Operation Manual
The FoamPro System 1600/1601 is an electric motor
driven flow-based proportioning system that measures
water flow and then injects the proportional amount of
foam concentrate to maintain the preset percentage.
The basic FoamPro 1600/1601 system is shown in
Figure 1. The system will accurately deliver from
0.1% to 1.0% foam concentrate to the foam injector
fitting. The flowmeter measures the water flow and
sends a signal to the motor driver control. Another
sensing device 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
the 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 the water flow.
Foam concentrate is injected directly into the water
stream on the discharge side of the water pump. It
is then fed as foam solution by the main fire pump
into a standard fog nozzle, an air-aspirated nozzle, or
CAFS equipment.
Figure 1
FoamPro 1600/1601 System Layout
Since foam is injected on the discharge side of the fire
pump, and check valves are to be used at installation,
there is no foam concentrate contamination of the
booster tank, fire pump and relief valve.
Order optional system components listed in Section 3
to accommodate system design and requirements.
FoamPro 1600 Series proportioners are designed
for Class A foam concentrate (per NFPA 1150)
applications. Full pump performance is realized
with concentrate viscosities up to 500 cps when
concentrate supply line design and installation
recommendations are followed. As viscosity
increases, diminished flow may affect pump
performance. Because of numerous variables;
including pump design, foam cell configuration, inlet
piping/components and system layout; please contact
FoamPro at 800-533-9511 for application specific
recommendations when foam viscosities of 500 cps
or higher are used.
2 A Quick Look at How the System Works
Water
Tank
Foam Tank
Shut-off
Valve
Water
Pump
Line
Strainer
Single Discharge Coverage
Multiple Discharge Coverage and Manifold
Check
Valve
Check
Valve
Flowmeter
Calibrate/
Inject Valve

5
Installation and Operation Manual
System 1600/1601
Installation and Operation Manual
STANDARD FOAMPRO 1600/1601 EQUIPMENT
3 System Component Description
4
Side Mount
(P/N 2510-0032)
Vertical Mount
(P/N 2510-0028)
56
8
7
23
1
The following components are packaged with the
FoamPro 1600/1601:
1. Control Module with Instructions
2. Molded Cables
3. Foam Pump Assembly
4. Low-Level Sensor (One required.
Not packaged with the unit. Order
separately.)
5. Calibrate/Inject Valve with Bushing (Attached
to the pump outlet connection.)
6. Inlet Line Strainer with Nipple
7. FoamPro 1” bore x 1-1/2” NPT size, 1-1/2”
or 2” NPT Paddlewheel Flowmeter or 1-1/2”
or 2” Foam Manifold with Paddlewheel
Flowmeter and Waterway Check Valve
8. 1/2” NPT Foam Injection Check Valve (This
NFPA required check valve prevents water
from back flowing into foam systems.)

6
Installation and Operation ManualInstallation and Operation Manual
SYSTEM ACCESSORIES AVAILABLE
Polypropylene
Foam Tank(s)
8 gallon, P/N 1530-0005
12 gallon, P/N 1530-0012
20 gallon, P/N 1530-0022
Foam Manifold
1-1/2 inch Pipe, P/N 2660-0051
2 inch Pipe, P/N 2660-0052
Main Waterway Check Valve
1-1/2 inch NPT, P/N 3320-1001
2 inch NPT, P/N 3320-1002
Solid State Contactor
P/N 2510-0043
Nesconset, NY 11767 USA
System Placard
Single Tank, P/N 6032-0015
System Rating Placards
Model 1600, P/N 6032-0018
Model 1601, P/N 6032-0019
CAFS Power-Link
Interfaces FoamPro system with CAF system
P/N 2510-0063
Single Tank Flush Kits
Both Internal and External flushing kits
Internal Flush Kit, P/N 3430-0834
External Flush Kit, P/N 3430-0835
Main Waterway Check Valve
All stainless steel with Victaulic
ends and injection and drain ports
1-1/2 pipe, P/N 3320-0069
2 inch pipe, P/N 3320-0070
NFPA Calibration
and Test Kit
For use with 1600 thru 3012 systems
P/N 3430-0830
Remote Start/Stop Option
(Order with system)
Remote Simulated Flow Option
(Order with system)

7
Installation and Operation Manual
System 1600/1601
The FoamPro 1600/1601 system is provided with the major components and accessories required for installation.
Due to differences in chassis and apparatus configurations, the installer must provide 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 and 7.
FOAM CONCENTRATE SUCTION LINE
Corrosion-resistant fittings and hoses from the foam tank to
the inlet of the foam pump must be used. Use 3/4 inch [19
mm] minimum inside diameter or larger hose dependent
on the viscosity of the foam concentrate. Use components
that are rated for 23 in [584.2 mm] Hg vacuum and 50 psi
[3 BAR] pressure or greater. The components must be
compatible with all foam concentrates to be used. Fittings
used must be made of brass, 300 series stainless steel or
other corrosion resistant material. Before selection of hose
fittings, check for compatibility with foam concentrates to
be used. The use of clear suction hose is recommended
to allow viewing foam priming operations. The foam pump
must be positioned to allow no more than a 3 foot lift to a
positive suction head from the foam tank. A net positive
suction head (NPSH) is recommended.
FOAM CONCENTRATE DISCHARGE LINE
Fittings and hoses from the discharge of the foam pump
to the injector fitting must be supplied by the installer.
Hoses and fittings of 3/8-inch [9.5 mm] minimum INSIDE
diameter, rated at 400 psi [28 BAR] minimum working
pressure or maximum discharge pressure of the fire pump,
whichever is greater, must be supplied by the installer.
Fittings and hoses must be compatible with all foam
concentrates to be used. Use fittings of brass, 300 series
stainless steel or other corrosion resistant material that is
compatible with all foam concentrates to be used.
CHECK VALVES
NFPA requires installation of a check valve in the foam
concentrate injection line. To prevent foam concentrate
flow from the tank due to static head pressure, the foam
concentrate check valve shall have a 12 psi [0.6 BAR]
cracking pressure and shall be capable of withstanding the
pressures that will be generated in the foam injection line.
A check valve is also required in all water piping locations
where foam concentrate could drain back into pumps or
other components of the fire apparatus. As a minimum,
one check valve must be installed where the foam
solution water piping connects to the fire pump discharge
(FoamPro Main Waterway Check Valve is recommended).
Multiple drains that allow individual drain lines to
communicate may allow foam to short circuit past
the check valves; avoid this possibility. FoamPro
recommends separate drain valve(s) for the
discharge piping.
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 from the main apparatus
electrical system to the foam pump base system. Power
must be supplied directly from the apparatus battery
without any connections to other high power devices, such
as primer pumps, hose reels, auxiliary starters, light bars,
etc. with its own disconnect switch, or a switch or contactor
actuated by the battery disconnect switch, PTO or other
device. Use proper wire size to be able to supply the foam
system with the proper voltage and amperage required.
The minimum service is as follows:
1600/1601 12VDC requires 32 amps
1600/1601 24VDC requires 16 amps
Braided flat ground straps are required for ground
connections. The flat straps limit the RFI/EMI interference
encountered with radios, computers or other sensitive
electronic equipment.
CAUTION: Always disconnect the ground straps
and control cables from the control module or
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 to the
electronic components.
4 Installer Supplied Parts

8
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. Figure
2 shows the relative location of the FoamPro System
1600/1601 components. 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 FoamPro 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, foam pump and flowmeter.
Try to place components in locations that require the
least amount of hoses and fittings.
Position the foam pump unit in an area that is protected
from road debris and excessive heat buildup. Since
the master power switch and CAL/INJECT valve are
located on this unit, it is recommended that the foam
pump unit be installed in an accessible compartment
located in the vicinity of the operators panel.
Although the foam pump unit can be positioned with
a suction lift not to exceed 3 ft. (0.9 meters), the unit
can be positioned below the discharge of the foam
tank to provide for gravity feed to the foam pump.
Place the foam tank where the refilling can be
done with 5 gallon [19 liter] containers and other
methods suitable to the end user. Most water tank
manufacturers will build the foam tank into the booster
tank. When specifying a integral foam tank, 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 for the control module on the
operator panel of the apparatus. Consider the routing
path of the control cables from the control module to
the foam pump unit and low-level sensor. If necessary,
order longer or shorter cable assemblies to suit the
location demands.
CAUTION: Never attempt to cut or lengthen the
molded cables.
5 Installation Planning
Figure 2
System Component Location
Control Module
Foam Pump/Motor
Flowmeter
Foam Tank,
Fittings and Piping

9
Installation and Operation Manual
System 1600/1601
The following diagram (Figure 3) provides recommended guidelines for the location of the system components
that handle water, foam concentrate and foam solution.
Figure 3
FoamPro 1600/1601 System Piping
6 Plumbing Component Installation
Figure 4 FoamPro 1600/1601 Mounting Dimensions
(267.5mm)
10-17/32in.
(282.6mm)
11-1/8in.
(504.9mm)
19-7/8in.
To Calibration
Container
Foam Tank
Shut-off
Valve
Water
Pump
Line
Strainer
Foam Pump Motor
Single Discharge Manifold Discharge
Check
Valve
Check Valve/
Foam Injection Port
Flowmeter
Calibrate/
Inject Valve
A. FOAM PUMP/MOTOR BASE ASSEMBLY
The foam pump/motor base assembly may be mounted
in a horizontal or vertical 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. Figure
4 provides the mounting dimensions for the FoamPro
1600/1601 foam pump/motor base assembly. Flexible
hose is required to make the hose connections to the
FoamPro 1600/1601.
DO NOT hard pipe the system.
Position the foam pump so the main power on-off switch
is easily accessible. Also, consider access requirements
for checking and greasing the cam bearing of the foam
pump. Be sure the foam concentrate hoses can be
properly routed to the inlets and outlets on the foam
pump. The foam pump must be positioned to allow no
more than a 3-foot lift to a positive suction head from
the foam tank. A net positive suction head (NPSH) is
recommended. The foam pump/motor base assembly
must be mounted in an area to avoid excessive exhaust
system heat buildup.

10
Installation and Operation Manual
D. LINE STRAINER
The line strainer that is provided with the FoamPro
unit has 3/4-inch NPT female threaded ports and is
installed on the inlet port 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
operating (23 in. [584 mm] Hg and 50 psi [3 BAR]).
NOTE: If a pressurized water flush from one of the
discharges is incorporated, the plumbing and line
strainer exposed to this pressure must be rated at or
above the operating pressure of all other discharge
plumbing components (400 psi [28 BAR] minimum).
E. FLOWMETER
The FoamPro System 1600/1601 is designed to accept
flow reading signals from the FoamPro paddlewheel
style flowmeter.
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.
a. A minimum of 5 times the pipe diameter of straight
run pipe without any fittings is necessary upstream
of the flowmeter.
10 times is even better — the longer the straight
run, the lower the turbulence.
b. The downstream plumbing of the flowmeter is not
as critical; but again, straight runs without fittings
help maintain accurate flow readings.
c. Do not mount a flowmeter directly after an elbow
or valve. Valves create severe turbulence when
they are “gated-down”.
d. Last, try to mount the flowmeters in a position that is
accessible for routine inspection and maintenance.
Protect the foam pump base unit 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 compartment with easy
operator access is the recommended installation location.
B. DISCHARGE RELIEF VALVE
The discharge relief valve is installed on the outlet port of
the foam concentrate pump. It is provided to protect the
foam pump from excessive pressures. The relief valve is
factory set at 400 psi [28 BAR].
C. CAL/INJECT VALVE
The CAL/INJECT valve is mounted on the discharge
side of the foam proportioner. This valve shall be
accessible by the pump operator during normal
operations. The valve is a 3-way directional valve that
selects where the output of the foam pump will go.
Check to make sure the valve is installed properly.
Look at the ports as you move the handle, the
flow should go from the center port to each of the
other ports.
The hose and fittings from the INJECT port to the foam
injector fitting must be 3/8 inch (9.5 mm) minimum
INSIDE diameter and be rated at 400 psi [28 BAR]
minimum working pressure or maximum discharge
pressure of the fire pump.
The hose from the CAL/FLUSH port may have a lower
pressure rating since it is plumbed to the atmosphere
and will not receive high pressures. This hose is used for
calibrating the foam pump, pumping the concentrate into
a container to empty the tank or to assist in priming of the
foam pump. The hose from the CAL/FLUSH port must
be long enough to reach a container outside the truck.
This hose must be coiled for storage when not in use.

11
Installation and Operation Manual
System 1600/1601
F. INJECTOR FITTING (optional)
The brass injector fitting ensures the foam concentrate
is injected into the center of the water flow. The inlet of
the fitting is 1/2-inch NPT female thread, and the outer
threads are 1-inch NPT designed to fit a pipe tee that
is installed in the discharge piping of the fire pump (see
Figure 7). The injector may
also be inserted into a weld
fitting with 1-inch NPT female
threads. It MUST be mounted
in a place that is common to
all discharges which require
foam capability. This fitting is
not used if using a FoamPro
Main Waterway Check Valve.
A separate injection point
is not possible for each
discharge (see Figure 8).
Most foam concentrates by nature mix with water very
quickly, so each discharge from a manifold will receive
equal concentrations if the manifold is properly designed
and installed.
G. CHECK VALVES
A 1/2-inch NPT check valve meets NFPA requirements
for a non-return device in the foam injection system.
This prevents foam concentrate from flowing from the
foam concentrate tank into the main waterway due to
static head pressure, the foam concentrate check valve
shall have a 12 psi [0.6 BAR] cracking pressure and
shall be capable of withstanding the pressures that
will be generated in the foam injection line. It is always
a good idea to inject foam at a horizontal or higher
angle to allow water to drain away from the check valve
(see Figure 9). This will avoid sediment deposits or the
formation of an ice plug.
Figure 5
Flowmeter Placement
PADDLEWHEEL FLOWMETERS
The FoamPro paddlewheel-style flowmeter fittings
are specially designed tees and manifolds that make
inspection and maintenance of the flow sensor easy.
The threads of the tees are NPT. In horizontal runs, the
tees should be mounted as close to upright as possible
within the range shown in Figure 6.
Figure 6
Flowmeter
Position Range
Tee Shown without
Sensor Installed
Figure 8 Injector Fitting Placement for
Multiple Discharges
Injector
Fitting
(optional)
Figure 7 Injector
Fitting Installation
(optional)

12
Installation and Operation Manual
DO NOT OVER TIGHTEN.
The check valve in the water way is required to keep
foam solution out of the main pump and allow pump
priming without drawing foam into the piping.
H. 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 foam solution piping to prevent
contamination of the water tank and fire pump.
I. 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 concentrates (per NFPA 1150) are less
corrosive and therefore may not require flushing.
Figure 10 Recommended Pump Installation
Minimum length of Nipple for 1-1/2” [38.1 mm] Pipe
is 7-1/2” [190.50 mm]. Refer to table on Page 10 for
the recommended nipple lengths for different pipe
sizes.
Check Valve
Injection Port
Flowmeter
Drain Port
Main Waterway
Check Valve
Injector Above
Horizontal Plane
DO
DON'T
Injector Below
Horizontal Plane
Injector Above
Horizontal Plane DON’T
DO
Injector Below
Horizontal Plane
Figure 9-1 Foam Injector Position
Figure 9-2 Foam Concentrate Flushing
System Diagram
Foam Strainer
Mounted on Foam
Pump Inlet
From
Foam Tank
Swing Check
Valve
Check
Valve
3/4 in.
ID Hose
Flush Water
Shut-Off Valve
From
Fire
Pump

13
Installation and Operation Manual
System 1600/1601
ELECTRICAL CONNECTIONS
Follow the system electrical diagram (Figure 11) for proper
hookup of each of the electrical components. Complete
molded cable sets are provided with each FoamPro
system to make all the necessary connections. The cables
are color coded and “indexed” so they only go in the
correct receptacle and they can only go in one way. DO
NOT FORCE MISMATCHED CONNECTIONS. The
system can only perform when the electrical connections
are sound, so make sure each one is right.
SOME THINGS TO KEEP IN MIND
• DO NOT hook up the main power cables until all of
the connections are made to each of the electrical
components. The last connection should be the power
cable to the foam pump/motor base assembly.
• WARNING: This system contains a capacitor
on the input power. Connect the leads with the
battery off or disconnected. Current will flow even
with the master on/off switch. Do not connect
7 Electrical Equipment Installation
power or ground cables to other components with
high amperage outputs.
• DO NOT cut molded cables.
• Power must be supplied directly from the apparatus
battery without any connections to other high power
devices, such as primer pumps, hose reels, auxiliary
starters, light bars, etc. with its own disconnect switch,
or a switch or contactor actuated by the battery
disconnect switch, PTO or other device.
• Make sure you provide at least 32 amps of electrical
power for 12 VDC systems or 16 amps for 24 VDC
systems from the battery to the main power terminal.
Use 10 AWG (minimum) wire directly to the battery or
battery switch using a relay to power the system.
• The S1xx-xxxx systems are designed for 12-volt,
negative-ground systems only. The S2xx-xxxx
systems are designed for 24-volt, negative-ground
systems only.
• Do not mount the radio transmitter or transmitter
cables in direct or close contact with the FoamPro unit.
Figure 11 FoamPro 1600/1601 Electrical Wiring Diagram
Main Power
Terminal
Main Power
Switch
Simulated Flow
Switch
To Positive Battery
Connection, Battery
Switch Relay, or
Contactor
Ground Strap
(Flat Braided
Ground Strap)
with 3/8” Dia.
Mounting Hole
Control Module
Control Cable
Low-Level
Sensor
Flowmeter

14
Installation and Operation Manual
• Use care when installing molded cables. Count
pins or check color codes before connecting.
Bent pins caused by improper hookup can
prevent proper operation even when cables are
reattached properly.
• Before connecting the molded cables, inspect the
yellow seal washer in the female connector. If the
seal washer is missing or damaged, water can
enter the connector and cause corrosion of the pins
and terminals that will cause system failure.
• CAUTION: The cables shipped with each
FoamPro unit 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: Always disconnect the ground
straps and control cables from the control
module or 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 to the system components.
A. CONTROL MODULE
The control module is designed to be mounted in the
operator panel of the apparatus. The cutout needed
in the operator panel is found on Page 26 of this
manual. The module is secured with four #10 socket
head screws in the four holes in the face (see Page
26 for a mounting template). The display requires 5
inches [127 mm] minimum from the back of the operator
panel to clear wires and connectors. Make sure there
is enough clearance behind the operator’s panel for the
cables. Once the control module is mounted, connect
the control cable (red coded cable end) from the motor
driver box terminal to the 5 pin connector on the back of
the control module (see Figure 12). A color-coded decal
on the motor driver box identifies each cable connection
(see Figure 13).
Figure 12 Control Module Cable Connections
and Grounding
NOTE: Make sure the panel where the control
module is mounted has an adequate ground. For
stainless steel and vinyl-coated panels, a flat
ground strap must be attached from one of the four
screws holding the control module in place, to the
frame of the fire truck to ensure adequate grounding
(see Figure 12).
Connections are to be
made during installation.
5-pin Connector
Low-level Sensor
Switch Terminals
Figure 13
Motor Driver Box Connections

15
Installation and Operation Manual
System 1600/1601
NOTE: When the low-level sensor senses a low
concentrate condition, the system will operate
for two minutes unless the foam concentrate
level is restored. If the foam concentrate level
is not restored, the system will shut down after
two minutes.
A side-mount low-level sensor is available to be used if both
the top and bottom of the tank is not accessible. The side-
mount low-level sensor has 1/2-inch NPT threads and the
center of the switch must be located approximately 2 inches
[51 mm] from the bottom of the foam tank with the float
positioned on top of the switch to move up and down.
The side-mount low-level sensor must be sealed with a
suitable sealant to prevent concentrate leakage. After
installation, check operation of the side-mount low-level
sensor with a powered test light. With no foam in the tank,
the light should be on. If light does not come on, rotate the
side-mount low-level sensor until the test light is on. The
float should be allowed to swing up and down freely.
D. DC MOTOR
Provide adequate electrical power (32 amps minimum for
12 VDC or 16 amps for 24 VDC) from the battery. Use
10 AWG minimum wire directly to the battery or battery
switch. Long wire runs may require larger wire sizes for
proper operation.
See recommended wire size table on page 16.
E. ELECTRICAL POWER SUPPLY
Electrical devices can be damaged, or operate
intermittently when powered by a weak or erratic power
supply. The FoamPro 1600 Series systems are not any
different – the better the power supply, the better the
system will perform. Following the instructions that follow
will ensure the FoamPro system will perform at its best.
B. FLOWMETER CONNECTION
A molded cable is supplied, which connects from
the flowmeter to the 3 pin connector on the motor
driver module.
C. FOAM TANK CONNECTIONS
The foam tank low-level sensor must be mounted into the
bottom of the foam tank to monitor low foam concentrate
level. The switch has 1/8-inch NPT threads. Mount
the sensor in the bottom of the foam tank in an upright
position. Use a suitable sealant to prevent concentrate
leakage. There must be space under the tank for the
cable to be routed to the pump base assembly. Be sure
not to remove the float from the shaft on the sensor
assembly. If installed in the reverse position, the control
module light will blink once per second or remain on, and
the system will automatically shut down after two minutes
even if there is foam in the tank.
When the bottom of the foam tank is not accessible, the
low-level sensor float switch can be hung from a long
nipple attached to the top of the tank. Take care to ensure
the nipple is rigid enough to withstand the force of sloshing
foam when the vehicle is in motion. Make sure the low-
level sensor does not contact the side of the foam tank
when the vehicle is in motion. Since wire connections
must be made inside the nipple, a 3/8-inch NPT nipple
with 3/8 by 1/8-inch NPT reducer at the lower end is the
minimum size recommended.
CAUTION: The foam tank low-level sensor must be
utilized to protect the foam pump from dry running.
Failure to do so will void the warranty.
Connect the sensor wires to the low-level sensor cable
terminal block on the control module. The low-level switch
sensor cable may be shortened or spliced longer (use
18-22 AWG). It has pigtails at one end and is not polarity
sensitive.
Check low-level sensor operation after installation using
a powered test light. With no foam in the tank, the light
should be on. If this is not the case, remove the clip from
the end of the sensor. Remove the float and reinstall 180°
out of position. Reinstall clip.
Figure 14 Foam Tank Low-Level Sensor
Mounting Options
Top Mount
Low-Level Sensor
Side Mount
Low-Level Sensor
(Optional)
Bottom Mount
(Optional)

16
Installation and Operation Manual
Power and ground connections must come directly
from the battery to the connections shown in figure 11.
These connections must come directly from the battery
without any connections to other high power devices such
as primer pumps, hose reels, auxiliary starters, light bars,
etc., with its own disconnect switch, solid state contactor,
or a switch or contactor actuated by the master disconnect
switch, PTO switch, or other device. Ensure the switching
device is rated for at least twice the maximum amperage of
the system being installed.
See the Electrical Power Supply Schematic on page 17
and the Recommended System Fuse Size table below.
CAUTION: Connecting other high power devices to the
power or ground supply with the FoamPro system will
cause component damage.
The system maximum amperage draw is listed as follows
and must be protected with a fuse or breaker of minimum
size listed in the main power line to the system and
provides enough power and protection for the display,
driver, motor, and associated components. If attaching
other FoamPro products to the supply line, the fuse or
breaker must be sized accordingly. It is also recommended
to install a fuse or breaker of at least 50% of the main fuse
or breaker value on the main ground line. All component
power and ground connections must be common for all
FoamPro components.
Recommended System Fuse Sizes
System
Model
Operating
Voltage
Maximum System
Amp Draw
Minimum Fuse or
Breaker Size
1600 & 12 VDC 32 35
1601 24 VDC 16 20
•Always connect the primary 12 or 24 VDC positive lead
for the system directly to the battery or power switch
using appropriate AWG wire that is chemical resistant
and protected with a wire loom. Install the proper fuse or
breaker size in the line that supplies the main power to
the system.
•It is recommended to connect the ground lead for
the main system directly back to the battery using the
same AWG size as the main power line and it should
also be chemical resistant wire protected in a wire loom.
Installation of a fuse or breaker of at minimum of 50%
of the main power breaker in line with the ground to the
system is also recommended.
•Never connect the main power or ground leads to other
leads that are connected to high power components
such as primer pumps, hose reels, auxiliary starters, etc.
•CAUTION: The wires between the terminal block and
capacitor, as well as the input power wire, are not
protected by the system circuit breaker. Be careful not to
damage or short circuit these wires.
•Always make the connection to the primary power
supply the last step.
•Always ensure the connections are sound and tight to
avoid erratic or poor power and ground connections to
the components.
•Always make sure the Control Display and the Base
System are grounded to the chassis using at ground
straps to reduce potential RFI and EMI issues.
Recommended Wire AWG
System
Model
System
Voltage
Max
Amps 10 ft. 15 ft. 20 ft. 25 ft. 30 ft.
1600 & 12 VDC 32 10 8 6 4 2
1601 24 VDC 16 10 10 8 6 6

17
Installation and Operation Manual
System 1600/1601
F. Solid State Contactor
The usage of the optional solid state contactor is
recommended to help protect the FoamPro system
from excessive voltage surges that can take place in
fire apparatus systems. The solid state contactor also
has a higher life expectancy than mechanical relay
options used for this application.
The SSC allows the operator to easily power the
system up and to shut it down with the use of a simple
switch. The following diagram depicts the installation of
this accessory.
Master Disconnect Switch,
PTO Switch,
or Manual Switch
To Other Devices
Battery
Relay, or Solid
State Contactor
Appropriately Sized
Amp Fuse or Breaker
Common Power Connection
for other FoamPro Accessories
Common Ground Connection
for other FoamPro Accessories
Power Lead (+)
Ground Lead (-)
System Z Bracket Assy
Controller
Electrical Power Supply Schematic
Nesconset, NY 11767 US
A
Engage Switch
Open - Off
Closed - On
Ground
Ground
+ Power
to
FoamPro
Unit
Solid State Contactor
2510-0043
Battery
Solid State Contactor Installation

18
Installation and Operation Manual
Figure 15 RFI/EMI Bead Installation
FLOWMETER AND CABLES
The flowmeter tee must be grounded. If metal piping is
used, sufficient grounding may be present. However,
Victaulic joints, plastic pipe and rubber mounted pumps
interfere with proper grounding and an additional
ground strap is required. Connect a braided ground
strap at least 1/4 inch [6 mm] wide from the flowmeter
tee to the apparatus frame to ensure proper grounding.
A #6-32 UNC tapped hole is provided on the flowmeter
tee for attaching the ground strap.
Making round coils of extra control and flowmeter
cables in the pump compartment can act as an
antenna. While the flowmeter and control cables
cannot be shortened, various lengths of cable are
available to minimize the “extra” cable in the truck.
(See parts list in Section 13 for part numbers of
different size control and flowmeter cables.) When
routing control and flowmeter cables, take care to avoid
routing them next to antenna cables, radio power lines
and radio components. When there is extra cable,
double the cable back on itself and secure in a flat
bundle with plastic wire ties instead of making a round
coil (See Figure 16).
G. EMI/RFI SUPPRESSION
An EMI/RFI (Radio Frequency Interference)
suppression kit is included with each FoamPro
1600/1601. The clamp-on beads included in the kit,
when properly installed, along with proper grounding
of components will reduce the potential for radio
frequency interference. Additionally, make sure radio
cables and hardware are not located in the immediate
area where the FoamPro 1600/1601 equipment
is mounted.
Install clamp-on beads at the locations indicated in
Figure 15. A small amount of silicone adhesive is
necessary to ensure that the beads will not move after
installation. Use GE SILICONE II, electrical tape or
heat shrink tubing to keep the beads from moving after
installation. The clamp-on beads must be slid up as
close as possible to the connectors on the cable.
Figure 16 Extra Cable Storage
Motor Driver Box
Large RFI Beads
Modular Cable
Modular Cable
Wire Ties
Control
Module
Do
Don’t
Flowmeter
Cable
Flowmeter
Sensor
Small
RFI Beads
Small
RFI Beads
Control
Cable

19
Installation and Operation Manual
System 1600/1601
Electrical
• Low-level sensor is connected and the connections are sealed from moisture.
• Module connectors are correct and tight.
• Cable connections at the motor driver box are correct and tight.
• Flowmeter cable is properly connected to the Motor Driver Module and is tight.
• All cables and wires are secured and protected by loom from damage during operation.
• RFI/EMI beads are installed; control and flowmeter cables are properly folded and secured; radio antennas,
power lines and equipment are away from control and flowmeter cables.
• All components, Control Module, Flowmeter Tee, Pump Base, etc., are properly grounded with adequate size
wire and bare metal connections.
• Adequate current capacity, 32 amps minimum for 12 VDC systems or 16 amps for 24 VDC systems, is available
for the foam pump motor.
• Main switch on the motor driver box is in the ON position.
Liquid
• Flowmeter is mounted with flow arrow in the correct direction for water flow.
• Check valves are properly mounted in water and foam concentrate lines.
• Strainer is properly mounted for the direction of concentrate flow in the foam tank to pump line.
• Foam tank to the foam pump valve is in place and open.
• Injector fitting lines are proper size and connections are tight.
• CAL/INJECT valve is properly mounted and oriented for direction of concentrate flow.
• The injector is in a common point to supply foam concentrate to all discharges specified to have foam capability.
• Fill foam tank with a sufficient quantity of foam concentrate or water to allow system calibration. Minimum of 5
gallons required.
• Foam is properly primed.
SYSTEM POWER CHECK
Turn the main power on/off switch on the motor driver
module to the ON position. Turn the Control Module
switch to the ON position. The LOW CONC. light will
flash momentarily. This indicates the system is ready
to operate.
FOAM PUMP PRIMING CHECK
Turn the CAL/INJECT valve to the CALIBRATE or
FLUSH position. Provide a container to collect the
output that will be coming from the foam pump.
Turn the INJECTION RATE knob to the 1.0%
setting. Place the system into “simulated flow” and
engage the FoamPro system at the control module. Figure 17 Motor Driver Box
Simulated Flow Switch
8 Making Sure Everything is Working Right

20
Installation and Operation Manual
• Foam concentrate should begin flowing into the
container. If concentrate is not being pumped,
check first to make sure the foam pump is running.
If the pump is running, but no concentrate is being
delivered, then the pump is most likely not primed
completely. If the pump does not prime within
20-30 seconds, disengage the system by turning
the switch off.
• If the system has been installed properly, foam
concentrate should flow readily to the pump.
• Once foam flow is established, turn the system
off and turn the CAL/INJECT valve back to the
inject position.
If you are still having difficulty priming the foam pump in
your FoamPro system, do the following:
• Make sure foam concentrate tank shutoff valve
is open.
• Check to make sure there are no restrictions from
the concentrate tank to the inlet of the foam pump.
• Check to make sure there are no leaks in the
plumbing where air can enter the pump.
If the pump continues to have difficulty priming. You will
have to shut the foam tank shut-off valve OFF, turn the
calibrate/flush/inject valve to calibrate/flush position.
Remove the screen from the strainer and assist it with
priming by holding a garden hose, under pressure in the
strainer, where the screen was removed. This can be
done with the foam pump not running.
After establishing a water flow through the calibrate/flush
valve, remove the garden hose from the strainer; install
the screen back into the strainer. Turn ON the foam tank
shut-off valve and retry priming the system. After system
has primed, turn the calibrate/flush/inject valve to the
inject position or use flush system, if installed.
CALIBRATION
The FoamPro System 1600/1601 and flowmeter have
been calibrated at the factory. To recalibrate the system,
the following procedure may be followed:
1. Turn the CAL/INJECT valve to the CALIBRATE or
FLUSH position. Provide a container to collect the
output that will be coming from the foam pump.
2. Start the main water flow and set it to a known rate
and pressure.
3. Set the injection rate to any specific setting (usually
0.5% or 1.0%).
4. Turn on the Model 1600/1601 and run it for 3 to 5
minutes. Foam will pump into the container.
5. Measure the amount of foam in the container and
compare that to the calculated amount (main flow
rate X injection rate X minutes flowed [100 gpm X
0.005 (0.5%) injection rate X 5 minutes = 2.5 gal.
output]). If the amounts are significantly different,
remove the small black screw and o-ring on the
motor driver box with a 3/32 allen wrench (see
Figure 18). With a small slotted screwdriver, adjust
the screw inside the driver module. If the measured
flow is above what is expected, turn the screw
clockwise. If the measured flow is below what is
expected, turn the screw counterclockwise.
6. Repeat Steps 1 through 5 again and make any
further adjustments required.
7. Replace the adjustment cover screw after calibration
has been completed. This keeps water and dirt from
entering the driver module and prevents serious
damage to the unit.
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 10%.
9 Calibration and Setup