Waterous 70-35-GP User manual

12/7/2017

Operation Guide

Applies to Waterous Model

70-35-GP Rotary

Rev 5

Unit Serial Number ______________________

Waterous Company

125 Hardman Avenue South

South St. Paul, MN 55075 USA

651-450-5000

Fax: 651-450-5090

www.waterousco.com

Waterous 70-35-GP Rev 5

Page 2 of 24

Warnings, Cautions, and Notes

Warning

A warning alerts you to a procedure, practice or condition that may result in death or long

term injury to personnel or destruction of equipment.

Caution.

A caution alerts you to a procedure or condition that may result in serious

damage to equipment or its failure to operate as expected

Note: A note points out important information. Failure to read the note may not result in

physical harm to personnel or equipment. It may waste time and money.

Revision History

Revision

Date Issued

Comments

---

04/2005

Original Release

9/29/2006

Logo chg, reformatted, T/S guides added, added

Manual Auto-sync pic,

9/6/2007

Updated Service parts list

5/20/10

Updated per ECR 136

5/26/10

Compressor changed

Disclaimer: These instructions are guidelines only and in no way meant to be definitive. During installation, standard safety

precautions and equipment should be used where appropriate. Because the tools used and the skill/experience of

the installer can vary widely, it is impossible to anticipate allconditions under whichthis installationis made, or to

provide cautions for all possible hazards. Proper installation is the responsibility of the purchaser. All bolts,

setscrews, and belts must be checked prior to start-up AND after the initial operation. Damages due to poor

installation are the responsibility of the installer.

Waterous reserves the right to make modifications to the system without notice

Waterous 70-35-GP Rev 5

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Table of Contents

SECTION 1. OPERATING INSTRUCTIONS .....................................................................................4

A. Multiple Uses...............................................................................................................................4

B. Water Pumping Operations..........................................................................................................4

C. Foam Solution Operations............................................................................................................5

D. Compressed Air Foam Operations ...............................................................................................5

SECTION 2. SHUT-DOWN PROCEDURE........................................................................................7

SECTION 3. SERVICE AND MAINTENANCE...................................................................................8

A. Maintenance Schedule.................................................................................................................8

B. Maintenance Items.......................................................................................................................8

SECTION 4. CAFS NOZZLE / FLOW RATE / HOSE COMBINATIONS.............................................9

A. Nozzles........................................................................................................................................9

B. Foam Concentrate Ratios.............................................................................................................9

C. Hose............................................................................................................................................9

SECTION 5.SUGGESTED GUIDELINES FOR THE PRODUCTION OF MID-RANGE

COMPRESSED AIR FOAM.........................................................................................10

A. 1” Hose Diameter Jacketed........................................................................................................10

B. 1-1/2” Hose Diameter.................................................................................................................10

C. 1-3/4” Hose Diameter.................................................................................................................11

D. Master Stream ...........................................................................................................................12

SECTION 6. TROUBLESHOOTING - CAFS....................................................................................13

SECTION 7. TROUBLESHOOTING – PUMP..................................................................................17

SECTION 8. TROUBLESHOOTING – BASIC ENGINE ...................................................................21

SECTION 9. CONDITIONAL 5-YEAR WARRANTY POLICY...........................................................24

Figure(s)

Figure 1 Manual Auto-sync Controls.......................................................................................................4

Figure 2 Unit Dimensions and Controls.................................................................................................22

Figure 3 Basic CAFS Schematic...........................................................................................................23

Waterous 70-35-GP Rev 5

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SECTION 1. OPERATING INSTRUCTIONS

Check the following fluid levels daily or prior to starting unit:

•Engine oil

•Compressor oil

•Foam concentrate

•Onboard water supply

A. Multiple Uses

The Waterous portable compressed air foam unit can be operated in several pumping

modes: water only, foam solution without compressed air and compressed air foam.

NOTE: Monitor compressor instruments during any and all operations.

Figure 1Manual Auto-sync Controls

B. Water Pumping Operations

All unit operations begin with pumping water. These steps must be followed for operations

involving pumping water, foam solution or compressed air foam.

Connect the hose to the discharge port.

Prior to starting the engine, the Auto-Sync control should be in the UNLOAD, a position which

allows the air compressor to "free wheel" without pumping air.

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•If pumping water from an onboard booster tank, fully open the tank to pump valve. If

pump from an overboard source, the tank to pump valve should be fully closed.

•If so equipped, turn on the main electrical power switch to the CAFS unit.

•To start the engine, open the throttle to approximately 1/4, close the choke if necessary,

move the ignition switch to the "ON" position, then to the start position to crank the

engine until it starts.

•Throttle-up to desired pressure. If pump pressure is absent, it will be necessary to prime

the pump utilizing the Waterous Manual Primer.

•To prime,

a) Open the1/4 turn Priming valve.

b) Pump primer until water comes out of the outlet hose

c) When the water discharge pressure gauge rises, the pump is primed.

d) After prime is achieved, close the Primer valve.

•Open thedischarge valve and throttle-up to desired pressure.

CAUTION:

Running the unit for extended periods with a dry fire pump can cause damage to

the pump.

C. Foam Solution Operations

Follow the instructions above for water pumping operations.

a) Attach the foam concentrate supply line to the FPS and foam pail, then open the

concentrate metering valve in the supply line.

b) Set the pump to the desired pressure (approximately 125psi).

c) Water and foam concentrate will now exit the FPS into the hose line. Foam

concentrate will be less than 1.0% under normal operating conditions.

d) If the foam produced is too dry, slowly close the metering valve towards 0 (0 equals

fully closed and 5 equals fully open).

e) Following any use of the FPS with foam concentrate, and prior to shut down for any

extended period, the foam concentrate metering valve should be closed, and clean

water should be allowed to flow through the FPS to clean itself. The check valve in

the foam concentrate supply line should be periodically removed and rinsed to insure

proper foam concentrate flow.

D. Compressed Air Foam Operations

Follow the instructions above for foam solution operations. Safe operations dictate the

presence of foam concentrate in the water stream prior to the injection of compressed air. If

foam concentrate is not present, a condition known as "slug flow" will occur. This is where

unmixed water and air is discharged through a nozzle in an erratic manner.

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Discharge pressures for compressed air foam operations typically range between 80 and 100

PSI in a flow state. Set water discharge pressure at the desired level.

NOTE: Compressed air foam does not have the hydraulic characteristics of plain water or

foam solution. Therefore, standard pump hydraulics practices do not apply to CAFS

operations.

1. Move Auto-Sync control to the AUTO position. Air pressure as shown on the air pressure

gauge should rise to within plus or minus 5% of the water discharge pressure. The Auto

Sync system will balance the air and water pressures throughout a range of 40 PSI up to

120 PSI. Optimal compressed air foam system performance occurs at discharge flow

pressures of 80-100 PSI.

2. Open the discharge gate valve approximately 1/4 to 1/2 open. The foam expansion ratio

is set by controlling the amount of foam solution entering the discharge stream. High

solution flows restrict the amount of air admitted and result in lower expansion or "wet"

foam. To produce higher expansion or "drier" foam, simply gate back the amount of

solution admitted.

3. Fully open the air valve to admit compressed air into the discharge, then adjust the

solution flow to produce the desired foam consistency.

Foam is formed during the transition through the hose. To produce acceptable finished

foam, sufficient hose length must be provided on the discharge. Refer to Section on

“Suggested Guidelines for the Production of Mid-Range Compressed Air Foam” for

minimum hose lengths for CAFS operations.

WARNING

Nozzle reaction force is significantly increased at the time the nozzle valve is opened in

compressed air foam operations. OPEN CAFS NOZZLES SLOWLY!

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SECTION 2. SHUT-DOWN PROCEDURE

1. Close air valve(s)

2. Turn off Foam proportioner by moving the selector handle to zero

3. Flow clear water through dischargehose(s) until no bubbles are present

4. Close discharge valve

5. Move Auto Sync control to UNLOAD

6. Shut engine down

WARNINGS:

•Compressed air can be dangerous. Read and understand the operating

instructions for the Waterous compressed air foam unit and individual

components prior to operating.

•DO NOT use the compressed air foam unit as an air source for SCBA or any

breathing air supply.

•Discharge outlets that are capped, hose lines that are valved and charged may

contain compressed air. Relieve all pressure BEFORE attempting to remove

any caps, fittings, nozzles, or to perform maintenance to prevent serious

personal injury.

•Nozzle reaction force is significantly increased at the time the nozzle valve is

opened in compressed air foam operations. OPEN CAFS NOZZLES SLOWLY!

•Operating the compressed air foam unit with water and compressed air

pumped through a discharge without foam concentrate will create a potentially

dangerous condition known as "slug flow"; where unmixed pockets of water

and air are passed through the nozzle, causing erratic nozzle reaction.

•For compressed air foam operations, use only fire hose that is rated at 200 PSI

or higher working pressure.

•The unit operator should have a thorough understanding of "Boyle's Law" (The

law of compressed gases) prior to operating the compressed air foam unit.

•It is recommended that the operator wear/use full safety equipment (i.e. gloves,

eye protection) on the fire grounds and when operating this system.

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SECTION 3. SERVICE AND MAINTENANCE

Refer to the included manuals for service and maintenance information on the following individual

components:

•Engine

•Air Compressor

•Foam Proportioner

A. Maintenance Schedule

Check oil level

and for oil leaks

Change Oil

Filter

Daily or After Each Use

Annually

Every 24 Months

B. Maintenance Items

COMPRESSOR

Part#

AIR FILTER:

CO45002 (1)

2030040

COMPRESSOR OIL

ISO 68 Non-foaming

ENGINE

(refer to Engine Manual for Maintenance Schedule)

Part#

AIR PRE-FILTER:

692520 (4)

6030037

AIR FILTER:

692519 (4)

6030036

OIL FILTER:

492932 (4)

6030038

FUEL FILTER:

691035 (4)

6030039

SPARK PLUGS

491055 (4)

6030040

ENGINE OIL:

Refer to Engine Manual

BELTS

Part#

PUMP:

8MGT-1120-12 (3)

1030027

COMPRESSOR:

8MGT-896-12 (3)

1030024

(1) = Donaldson (2) = Mann & Hummel (3) = Gates

(4) = Briggs & Straton

Waterous 70-35-GP Rev 5

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SECTION 4. CAFS NOZZLE / FLOW RATE / HOSE

COMBINATIONS

A. Nozzles

Compressed air foam can be discharged through various types and sizes of nozzles. Fog

nozzles break-down the bubble structure of the foam, resulting in "wetter" or reduced

expansion foam. The preferred way to make foam is utilizing smooth bore nozzles with a

given hose diameter. Smaller tips will discharge "wetter" foam.

B. Foam Concentrate Ratios

Proportioner settings of 0.2% and 0.6% are typically adequate to produce compressed air

foam that is formed in a hose line and used on Class A combustibles. Higher settings will

result in”drier" appearing foam. Lower settingsmay result in "slug flow" or discharge pulsation

caused by insufficient foam concentrate in solution to form foam in the hose line.

C. Hose

Utilize fire hose that is rated by the hose manufacturer for use with CAFS. Since the foam is

formed during its transition through the hose line, it is important to utilize the minimum

recommended hose lengths, unless a static mixer is utilized. There is significantly less friction

and head loss with compressed air foam as compared to water or foam solution. Hence,

effective fire streams can be achieved with longer hose lays. Refer to the Suggested

Guidelines for the Production of Mid-Range Compressed Air Foam.

NOTE: Compressed air foam systems have the ability to produce foam of shaving cream

consistency. While this type of foam is highly stable and possesses a long drain time,

it is essential to ensure that the foam will release sufficient water to extinguish a fire

in a direct attack situation. This type of foam is typically suited for defensive

operations such as exposure protection, barriers or fuels pre-treatment.

Waterous 70-35-GP Rev 5

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SECTION 5. SUGGESTED GUIDELINES FOR THE

PRODUCTION OF MID-RANGE COMPRESSED AIR

FOAM

A. 1” Hose Diameter Jacketed

1 GPM to 1 CFM

½” Tip Solution Flow: 15 GPM (56.78 LPM)

Air Flow: 15 CFM (0.42 m3/min)