Waterous Foam Manager User manual

All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.All content in this instruction is property of the Waterous Company. Instructions subject to change without notice.
Installation Instructions
Foam ManagertSystem
with AdvantusRSection
3026
Form No.
F-1031
Issue Date Rev. Date
05/11/1201/18/08
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA [phone]
Instructions subject to change without notice.
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components 3, 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication:
Foam Pump Oil Fill 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation:
Fire Pump Mounting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foam Pump Mounting:
(Only if Foam Pump was Shipped Loose)
Mounting Foam Pump 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Cables and Mounting Bracket:
Advantus 3 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advantus 6 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Components:
Advantus Foam Pump:
OIT (Operation Interface Terminal - Control Panel) 9. . . . . . .
Optional Dual OIT (Control Panel) Kit 9. . . . . . . . . . . . . . . . . . .
Instruction Panel 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Schematic and Rating Panels 9. . . . . . . . . . . . . . . . .
Foam Concentrate Connection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foam Tank 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foam Tank to Advantus Foam Pump Connection 10. . . . . . . . . .
In-Line Foam Concentrate Strainer 10. . . . . . . . . . . . . . . . . . . . . .
Optional Foam Tank Level Switch 10. . . . . . . . . . . . . . . . . . . . . . .
Inject/Bypass Valve 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water/Foam Solution Distribution 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Water Drains:
Water Distribution Check Valves 11. . . . . . . . . . . . . . . . . . . . . . . .
Foam Manifold 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring:
Electrical Components 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power to Foam Pump 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Schematic 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cables and Grounding 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foam Tank Switch - Single or Dual 15. . . . . . . . . . . . . . . . . . . . . .
Foam Pump Calibration: 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents
Foam Manager System with Advantus

F-1031, Section 3026 Page 2 of 17
Introduction
This instruction covers the installation of a Foam ManagertFoam System.
The Foam Managertsystem is factory mounted on a Waterous CS, CSU, CM
or CMU midship pump.
Foam Manager™ System
Other installation instructions available:
•CS, CSU, CM, CMU Series Fire Pump, F-1031, Section 3011
•Priming System, F-1031, Section 3006
•Manifold Drain Valves, F-1031, Section 3008
•Pressure Control System, F-1031, Section 3010
Before proceeding with the installation of the Foam Managert, read all the
instructions carefully. Check the appropriate dimensional drawings in the
Engineering Manual as needed.

F-1031, Section 3026 Page 3 of 17
S
y
stem Com
p
onents
Listed below are the Foam ManagertFoam System's standard items furnished, optional items from Waterous and items not furnished by Waterous.
Standard Items Furnished
Ref. No. Description
1AdvantustFoam Pump (Proportioner)
Pump Mounted (Shown) or Shipped Loose for Remote Mounting by OEM
2Foam Pump Inject/Bypass Valve
3In-Line Foam Concentrate Strainer
4Foam Manifold
5AdvantustFoam Pump OIT (Control Panel)
6AdvantustOperation Instruction Panel Plate
7OIT Cable
Items not Furnished by Waterous
Description
Discharge Ball Valves and Check Valves
Foam Concentrate Tank and Plumbing
Drain Lines from Manifold and Discharge Check Valves
Optional Items from Waterous
Description
Foam Tank Level Switch
Dual OIT (Control Panel) Kit
Dual Foam Tank Selector Kit
Advantus Rating Panel Plate
Advantus System Schematic Panel Plate
OIT (Control Panel) Extension Cable
Static Mixer
Note: See the next page for diagram.

F-1031, Section 3026 Page 4 of 17
System Components
56
37
Items Shipped Loose
with Advantus Foam Pump
1
4
2
3
To Foam Tank

F-1031, Section 3026 Page 5 of 17
Lubrication
Foam Pump Oil Fill
Check the oil level of the foam pump and add if necessary:
AdvantusRFoam Pump Oil
Foam Pump Model Level from Top of Oil Fill Port Use Oil
Advantus 3 3/4 inch (19 mm) Synthetic 10W-30 (Mobil 1 recommended)
Advantus 6 1 inch (25 mm)
Advantus 3 Systems Advantus 6 Systems
Oil Fill
Oil Drain
Oil Fill
Oil Drain

F-1031, Section 3026 Page 6 of 17
Installation
Fire Pump Mounting
For fire pump mounting instructions, see F-1031, Section 3011, CM/CS Installation Instructions.
Foam Pump Mounting
Required if the Foam Pump is not mounted on the Fire Pump at the factory (shipped loose).
Install Foam Pump in Apparatus:
The Motor / Pump Assembly must be mounted horizontally. The base must be
anchored to a surface or structure that is rigid and of adequate strength to
withstand the vibration and stresses of apparatus operation. For dimensions of
mounting bracket, see page 7 (Advantus 3) or page 8 (Advantus 6).
Flexible hose is required to make the hose connections from the Motor / Pump
Assembly to the foam tank.
DO NOT hard pipe the system.
Consider access requirements for checking the foam pump. Be sure the foam
concentrate hoses can be properly routed to the inlets and outlets on the foam
pump.
Foam concentrates should gravity feed to the foam pump inlet from the foam
tank. However the systems are capable of drafting up to one meter vertically.
The Motor / Pump Assembly must be mounted in an area to avoid excessive
exhaust system heat buildup.
Protect the hoses and wiring to prevent chafing and abrasion during operation
of the foam system.
Protect the Motor / Pump Assembly from excessive road spray and debris.
Although the system is sealed and designed to be resistant to the harsh envir‐
onment of fire fighting apparatus, a protected compartment with easy operator
access is the recommended installation location.
Install foam injection hose and cables between Foam Pump and Foam
Manifold:
Advantus 3 Systems: See page 7.
Advantus 6 Systems: See page 8.

F-1031, Section 3026 Page 7 of 17
Foam Pump Mounting (Continued)
AdvantusR3 Hose, Cables and Mounting Bracket
Foam Injection Hose Connections, Mounting Bracket Dimensions Cable Connections
Foam Pump
Mounting Bracket
1/2 NPT x 3/8 NPT Adapter
Foam Manifold
(Mounted on Fire Pump)
90_Street Elbow,
1/2 NPT
48 in. Hose furnished, if longer hose required, contact Waterous
Note: If longer cables are required, cable extensions are available, contact Waterous.
Follow electrical wiring instructions on pages 12 through 15.
See page 14 for OIT cable connection

F-1031, Section 3026 Page 8 of 17
Foam Pump Mounting (Continued)
AdvantusR6 Hose, Cables and Mounting Bracket
Foam Injection Hose Connections, Mounting Bracket Dimensions Cable Connections
Foam Pump
Mounting Bracket
1/2 NPT x 3/8 NPT Adapter
Foam Manifold
(Mounted on Fire Pump)
90_Street Elbow,
1/2 NPT
48 in. Hose furnished,
if longer hose required,
contact Waterous
Note: If longer cables are required, cable extensions are available, contact Waterous.
Follow electrical wiring instructions on pages 12 through 15.
See page 14 for OIT cable connection

OIT (Control Panel) - See Page 14 for Cable Connections
Instruction Panel
Optional Schematic and Rating Panels - Advantus 3 Shown
DPL82983
DPL82983
DPL82983
F-1031, Section 3026 Page 9 of 17
Panel Components
OIT (Control Panel)
Determine a location for the Operator Interface Terminal (OIT) on the operator
panel of the equipment.
·Consider the routing path of the cable from the OIT to the pump / motor
driver assembly (see Page 13).
·If necessary, order longer or short cable assemblies to suit the location
demands
NOTE: Make sure there is enough clearance behind the OIT assembly
for the cable.
Optional Dual OIT (Control Panel) - Follow instructions furnished with kit.

Advantust 3 Systems Advantust 6 Systems
Foam Tank Hose Connection,
1/2 in. NPT
Foam Tank Hose Connection,
1 in. NPT
Inject/Bypass Valve
In-line
Strainer
In-line
Strainer
IL2959
Foam Tank Connection to Advantus®Foam Pump
Flexible hose is required to make the hose connections from the foam pump to
the foam tank. Note hose from the foam tank to the foam pump is not fur
nished by Waterous. The in-line foam concentrate strainer must be installed in
the line and be accessible for maintenance.
To ensure adequate concentrate supply, size hose as follows:
·Advantus 3 - minimum of 3/4 inch ID tubing
·Advantus 6 - minimum of 1 inch ID tubing
Foam Tank Connection to Advantus®Foam Pump
When specifying an integral foam tank, make sure provisions are made for in
stallation of the optional low tank level sensor as well as foam suction connec
tions and tank drainage according to NFPA.
Most water tank manufacturers will build the foam tank into the booster tank.
1. Place the foam tank so that refilling can be done safely.
2. Foam concentrates should gravity feed to the foam pump inlet from the foam
tank. However, the systems are capable of drafting up to 1 meter vertically.
Foam Tank - Not Furnished by Waterous
Foam Concentrate Connection
Optional Foam Tank Level Switch
Inject / Bypass Valve
Waterous offers two types of tank level switches as shown below.
1. Install in tank according to NFPA (see Page 15 for wiring details).
Side MountBottom Mount
1/2 in. NPT
1/8 in. NPT
The Inject / Bypass valve is mounted on the discharge side of the foam pump.
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 should have
a minimum rating of 3/8 of the maximum fire pump discharge pressure.
The hose from the bypass 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 pumping the concentrate into a container to empty the tank or to assist
in priming of the foam pump. The hose from the bypass port must be long
enough to reach a container outside the truck. This hose must be coiled for
storage when not in use.
F-1031, Section 3026 Page 10 of 17
CAUTION
Shut-Off Valves. May cause damage to the foam pump.
Never install shut-off valves between the pump and discharge
pressure regulator or in the regulator bypass line.

Check Valve
3/4 NPT Drain Tap,
Plumb to an isolated drain valve
IL2981
Water / Foam Solution Distribution
Water Distribution Check Valves
WATER/FOAM
DISTRIBUTION
High Flow Water Check Valve Discharge Ball Valve
Check Valve Drain
Foam Manifold
All CAFS discharges should be equipped with water check valves. Water and
foam can be trapped between the check valve and the discharge valve. In
order for all water/foam to properly drain, water drains need to be plumbed to
each check valve. These drains should be isolated drains.
F-1031, Section 3026 Page 11 of 17
1. Waterous furnishes a mix manifold mounted on the pump with 2-1/2 in.
Victaulic or 3 in. Victaulic discharge.
2. Distribution manifolds, piping and valves are not furnished by Waterous.
3. All Discharges should be equipped with water check valves.
4. Optional static mixers feature a six element mixing array inside a stainless
steel pipe. Measuring 14 inches in overall length and 2-1/2" inches in
diameter, the static mixers can be fitted with Victaulic, NPT or both con
nections on the inlet or outlet.
The optional static mixers are mounted downstream of the valve.
5. See drawing below for draining of check valves.
Water Drains
(Also refer to F-1031, Section 3008, Drain Valve Installation Instructions.)

F-1031, Section 3026 Page 12 of 17
Electrical Wiring
Electrical Components
CAUTION
Follow the systems electrical diagrams on the following pages for
proper hookup of each of the electrical components. Complete
molded cable sets are provided with each Advantus system to make
all the necessary connections.
1. The cables and receptacles are keyed so they only go in the correct
receptacle and they can only go in one way.
2. DO NOT force mismatched cable connections. They system can only
perform when the electrical connections are sound, so make sure one
is right.
3. 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.
4. Disconnect the leads of the battery.
5. DO NOT cut molded cables.
6. Make sure you provide at least 60 Amps of electrical power for 12 VDC
systems or 30 Amps for 24 VDC systems from the battery to the main
power terminal. Use 8 AWG (minimum) wire directly to the battery or
battery switch.
7. The system is designed for 12 or 24 volt negative ground direct current
systems only.
8. Use care when installing molded cables. Count pins before connecting.
Bent pins caused by improper hookup can prevent proper operation
even when cables are reattached properly.
9. 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.
10. The cables shipped with each Advantus 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.
11. Always disconnect the ground straps and control cables from the
Operator Interface Terminal (OIT) or other Advantus equipment before
electric arc welding at any point on the apparatus. Failures to do so
may result in a power surge through the unit that could cause irrepar
able damage to the system components.
Power to Foam Pump
The large circuit breaker (see Page 13) is used to connect the 12 or 24 VDC
input power.
Make sure you provide adequate electrical power from the battery. Use 8
AWG (minimum) wire directly to the battery or battery switch. Long wire runs
may require 6 or 4 AWG wire for proper operation.
Recommended Wire Sizes
Wire Size Wire Length (approx.)
8 AWG 10-20 feet
6 AWG 20 feet to 30 feet
4 AWG 30 feet or more
Power Requirements
Advantus System Power Required
12 VDC 24 VDC
#3 60 Amps 30 Amps
#6 80 Amps 50 Amps
Power Supply
Electrical devices can be easily damaged by a weak or erratic power supply.
The better the power supply, the better the Advantus systems will perform. At
maximum output, the Advantus 3 system can draw 60 Amps at 12 VDC (30
Amps at 24 VDC). The Advantus 6 system can draw 80 Amps at 12 VDC (50
Amps at 24 VDC).
Connect the ground lead from the chassis frame or the negative battery ter
minal. Use the same size wire as the power lead.
DO NOT connect the main power leads to small leads that are supplying some
other device such as a light bar or siren.
CAUTION
Be careful not to damage or short circuit the wires leading to the circuit
breaker. Only the Advantus system is protected by the circuit breaker.

F-1031, Section 3026 Page 13 of 17
Advantus Foam Pump Schematic
Chassis Ground
+12 or 24 VDC
(from vehicle)
Conductivity Probe
Conductivity
Probe
Flow Sensor
To Product Sensor
on Foam Pump Motor
Resettable
Voltage
Breaker
Ground
Auto Run
Tank B Float Switch
Tank A Float Switch
Tank B Select
Power to the
Pump Motor
Operator Interface Terminal
Terminal Block
Gray
Black Foam Pump
Control Box
(see Pages
13 & 14)

F-1031, Section 3026 Page 14 of 17
Foam Pump Cables
1. Connect the control cable (8 pin) from the control box terminal to the back
of the OIT control panel. Labels on the control box identify the terminal as
“OIT". See Page 13, Advantus Foam Pump Schematic.
2. All other cables for the manifold flow sensors.
·Foam pump installed on fire pump at factory:
Cable connections completed at factory.
·Foam pump shipped loose for installation by OEM:
See page 7 (Advantus 3) or page 8 (Advantus 6) for cable connec
tions.
3. Making round coils of extra OIT and flow sensor cables in the pump com
partment can act as an antenna. While the flow sensor and OIT cables
cannot be shortened, various lengths of cable are available to minimize
the “extra" cable in the truck. When routing cables, take care to avoid
routing them next to antenna cables, radio power lines and radio compon
ents. 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.
CAUTION
Never attempt to cut or lengthen the molded cables. Cables can be
daisy-chained to obtain longer lengths.
CAUTION
Always disconnect the ground straps and control cables from the Operator
Interface Terminal (OIT) or other Advantus equipment before electric arc
welding at any point on the apparatus. Failure to do so could result in a
power surge through the unit that could cause irreparable damage to the
electronic components.
Foam Manifold Grounding
The manifolds must be grounded. If metal piping is used, sufficient grounding
may be present. However, Victaulic joints, plastic pipe, rubber hoses and
rubber mounted pumps interfere with proper grounding and an additional
ground wire may be required.

F-1031, Section 3026 Page 15 of 17
Foam Tank Switch - Dual or Single

F-1031, Section 3026 Page 16 of 17
Foam Pum
p
Calibration
The Advantus system is able to be field calibrated using the control function buttons on the operating interface terminal (OIT), see figure below. Only units of
measure, water flow and the foam percentage default can be field set.
A. Entering Calibration Mode
1. Entering calibration is accomplished by using the control unit functions
buttons.
2. To enter this function, press and hold the SELECT button for minimum
of five seconds.
3. Continue to hold the SELECT button.
4. While the SELECT button is depressed, push the UP and DOWN
arrow buttons at the same time. The display will show CAL for two
seconds and then display F1.
5. Use the UP button to advance to the next parameter (F2, F3, F4).
6. Use the DOWN button to back up to a previous parameter (F2, F1).
7. To edit a parameter, press the SELECT button at the associated Fn
prompt.
B. F1 - Default Mix Percentage
1. At the F1 prompt, press the SELECT button.
2. Use the UP and DOWN arrow buttons to select the default FOAM %.
The only foam % selections will be .1%, .2%, .3%, .4%, .5%, .6%, .7%,
.8%, .9%, 1.0%, 3.0% and 6.0%.
3. When finished, press the SELECT button to save the displayed value.
C. F2 - Units of Measurement
The units of measurement must be selected prior to any calibration func
tions. Units of measurement are U.S. Gallons, Imperial Gallons and Liters.
1. Push the SELECT button at the F2 prompt. The display will show the
current setting.
2. Use the UP and DOWN arrow buttons to select one of the following
measurement units:
·GAL will select U.S. Gallons
·IPL will select Imperial Gallons
·LTR will select Metric Liters
3. Pushing the SELECT button will save the displayed selection. This will
allow for calibration of the water flow in the units of measurement selected.
D. F3 - Flow Rate Calibration
1. Press the SELECT button at the F3 prompt. The current measured
flow rate will be displayed. Establish a flow using an accurate flow
measuring device.
2. Once this is established, press the UP or DOWN button to advance
to the calibration step. If the displayed flow rate is correct, press the
SELECT button to return back to the F3 prompt. If there is insufficient
flow, the display will show LoFL for two seconds, then return back to
the F3 prompt.
3. The display will now display 50 (starting value) or the last calibration
value entered.
4. Use the UP and DOWN arrow buttons to change the displayed value
to match the actual flow rate according to the flow measuring device. If
the button is only pressed momentarily, the display increments or
decrements by one. If the button is held, the display will increment or
decrement by five.
5. Once the correct flow is achieved, pushing the SELECT will save the
setting and return to the F3 prompt.
E. F4
System can be locked out after calibration and setup to avoid accidental
changing.
F. Saving Calibration
To save all the calibration settings to flash memory, press the FOAM
button while at the Fn prompt. The data will be stored and the unit will
return to normal operation.
Operator Interface Terminal

F-1031, Section 3026 Page 17 of 17
Troubleshootin
g
Guide
It is important to know what to do if your foam system is not operating properly. This troubleshooting guide should help you diagnose, isolate and fix the problem encoun‐
tered.
Problem Cause Fix
Poor foam solution (wet or dry)
Using wetting agent in place of foam Flush system and install Class “A” foam.
Lack of foam
Check if the Foam Pump is on. Check if there is foam in the res‐
ervoir. Make sure the foam supply valve is on and the Y strainer
clean.
Foam in water system
Foam dumped into the water tank Flush water tank and pump until foam is cleared.
Foam cell is leaking into water tank
Condition applies to tanks utilizing a common wall(s) between
the foam tank and the water tank. If a leak is confirmed, repair
the foam tank and flush the water tank and pump until foam is
cleared.
Foam proportioning manifold check valve malfunction
If the above conditions have been corrected, the final cause for
foam in the water tank may be the result of a malfunctioning
foam manifold check valve. To troubleshoot, cap off one foam
discharge that is plumbed to the foam manifold, open that dis‐
charge valve and increase the pump discharge to 30-40 PSI.
Disengage the pump and monitor the corresponding discharge
PSI gauge, looking for a drop in discharge pressure. If the PSI
drops, it indicates the foam manifold check valve is leaking and
requires repair.
Foam manifold drain plumbed into master drain. Supply a separate drain for foam manifold.