HUSKY 12 GPM - graftonfire.com · © 2012 Pierce Manufacturing Inc. Part No. PM-F-OM130-0212 HUSKY 12 GPM FOAM SYSTEM Operation & Maintenance Manual

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2 Pierce Manufacturing Inc. Part No. PM-F-OM130-0212

TABLE OF CONTENTS

FOREWORD

1 PURPOSE OF MANUAL ..................................................................................................................................... v

2 SCOPE ............................................................................................................................................................ v

3 CUSTOMER ASSISTANCE INFORMATION ............................................................................................................ v

SECTION 1. SAFETY

1-1 INTRODUCTION ............................................................................................................................................. 1-1

1-1.1 TO THE OWNER—OPERATION AND MAINTENANCE OF THIS APPARATUS ............................................ 1-11-1.2 DESCRIPTION OF “DANGER,” “WARNING,” AND “CAUTION” ......................................................... 1-1

1-2 LIST OF ABBREVIATIONS ............................................................................................................................... 1-2

SECTION 2. GENERAL

2-1 HUSKY 12 SPECIFICATIONS .......................................................................................................................... 2-1

2-1.1 FOAM PROPORTIONER .................................................................................................................... 2-12-1.2 SYSTEM CAPACITY ......................................................................................................................... 2-12-1.3 DISCHARGES ................................................................................................................................. 2-12-1.4 SYSTEM ELECTRICAL LOAD ............................................................................................................. 2-12-1.5 MAINTENANCE MESSAGE ................................................................................................................. 2-12-1.6 FLUSH SYSTEM ............................................................................................................................... 2-22-1.7 FOAM CONCENTRATE COMPATIBILITY .............................................................................................. 2-2

2-2 DESCRIPTION OF MAJOR COMPONENTS ........................................................................................................ 2-2

2-2.1 HYDRAULIC DRIVE SYSTEM ............................................................................................................. 2-22-2.1a HYDRAULIC GEAR PUMP ..................................................................................................... 2-32-2.1b HYDRAULIC OIL FILTER ....................................................................................................... 2-32-2.1c HYDRAULIC OIL RESERVOIR ................................................................................................ 2-42-2.1d HYDRAULIC OIL COOLER ..................................................................................................... 2-42-2.1e HYDRAULIC MANIFOLD BLOCK ............................................................................................. 2-5

2-2.2 FOAM SUPPLY SYSTEM .................................................................................................................. 2-52-2.2a FOAM CONCENTRATE TANK ................................................................................................ 2-52-2.2b FOAM SUPPLY VALVE ......................................................................................................... 2-62-2.2c FOAM CONCENTRATE PUMP ................................................................................................ 2-62-2.2d FOAM SELECTOR VALVE ..................................................................................................... 2-72-2.2e PANEL MOUNTED STRAINER / EXTERNAL PICK-UP CONNECTION .......................................... 2-82-2.2f PICK-UP HOSE ................................................................................................................... 2-92-2.2g FOAM CHECK VALVE ........................................................................................................... 2-9

2-2.3 WATER SUPPLY SYSTEM ................................................................................................................ 2-92-2.3a MANIFOLD AND MASTER DRAINS ....................................................................................... 2-102-2.3b IN-LINE WATER CHECK VALVE ........................................................................................... 2-102-2.3c WATER FLOWMETER ......................................................................................................... 2-11

2-2.4 CONTROL SYSTEM ........................................................................................................................ 2-112-2.4a CONTROLLER MODULE ...................................................................................................... 2-112-2.4b CONTROL HEAD ................................................................................................................ 2-12

© 2012 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / i

TABLE OF CONTENTS

SECTION 3. OPERATION

3-1 FOAM SYSTEM OPERATION ........................................................................................................................... 3-1

3-1.1 CLASS A FOAM - USING ON-BOARD FOAM TANK ............................................................................... 3-13-1.2 CLASS A FOAM - DRAFTING ............................................................................................................. 3-23-1.3 CLASS B FOAM - USING ON-BOARD FOAM TANK ............................................................................... 3-23-1.4 CLASS B FOAM - DRAFTING ............................................................................................................. 3-3

3-2 FLUSHING SYSTEM ....................................................................................................................................... 3-3

3-2.1 GENERAL FLUSHING INFORMATION ................................................................................................... 3-33-2.2 MANUAL FLUSH MODE ..................................................................................................................... 3-43-2.3 FLUSHING AFTER DRAFTING CLASS A FOAM .................................................................................... 3-43-2.4 FLUSHING AFTER DRAFTING CLASS B FOAM .................................................................................... 3-5

3-3 PRIMING SYSTEM .......................................................................................................................................... 3-5

3-4 FILLING FOAM TANK(S) ................................................................................................................................. 3-7

3-4.1 CLASS A TANK FILL (OPTIONAL) ...................................................................................................... 3-73-4.2 CLASS B TANK FILL (OPTIONAL) ...................................................................................................... 3-83-4.3 FILL THROUGH FOAM TANK FILL DOME ............................................................................................ 3-9

3-5 MANUAL MODE ............................................................................................................................................. 3-9

3-5.1 FLOWMETER OPERATION ............................................................................................................... 3-10

3-6 SET-UP MODE ............................................................................................................................................ 3-11

SECTION 4. MAINTENANCE

4-1 MAINTENANCE INTRODUCTION ....................................................................................................................... 4-1

4-1.1 TESTING AFTER SYSTEM MAINTENANCE ........................................................................................... 4-1

4-2 SET-UP & CALIBRATION ................................................................................................................................ 4-2

4-2.1 SET-UP MODE ................................................................................................................................. 4-24-2.2 ENGLISH/METRIC MODE .................................................................................................................. 4-24-2.3 CALIBRATE FLOWMETER MODE ........................................................................................................ 4-34-2.4 CALIBRATE FOAM PUMP (LVDT) TRANSDUCER ................................................................................ 4-34-2.5 CALIBRATE CLASS A FOAM MODE ................................................................................................... 4-44-2.6 CALIBRATE CLASS B FOAM MODE ................................................................................................... 4-54-2.7 SET CLASS A CONCENTRATE DEFAULT PERCENTAGE ...................................................................... 4-54-2.8 SET CLASS B CONCENTRATE DEFAULT PERCENTAGE ...................................................................... 4-64-2.9 SELECT SINGLE OR DUAL FOAM TANK SYSTEM ................................................................................ 4-64-2.10 SET DEFAULT FOAM SOURCE .......................................................................................................... 4-74-2.11 TANK FILL ENABLE/DISABLE ............................................................................................................ 4-74-2.12 SET AUTOMATIC FLUSH TIME ........................................................................................................... 4-84-2.13 AUTO START ................................................................................................................................... 4-84-2.14 DRAIN MODE ................................................................................................................................... 4-94-2.15 RESET MAINTENANCE REMINDERS ................................................................................................. 4-104-2.16 CHECK CURRENT SOFTWARE REVISION ......................................................................................... 4-10

ii / Husky 12 Foam System © 2012 Pierce Manufacturing Inc. All Rights Reserved.

TABLE OF CONTENTS

4-3 TROUBLESHOOTING .................................................................................................................................... 4-11

4-4 PERIODIC OPERATION ................................................................................................................................. 4-25

4-5 GENERAL MAINTENANCE PROCEDURES ....................................................................................................... 4-25

4-6 PREVENTIVE MAINTENANCE CHECKS AND SERVICE ..................................................................................... 4-26

4-6.1 INTRODUCTION .............................................................................................................................. 4-264-6.2 EXPLANATION OF COLUMNS ........................................................................................................... 4-26

4-7 AFTER EVERY USE INSPECTION .................................................................................................................. 4-27

4-8 WEEKLY INSPECTION .................................................................................................................................. 4-27

4-9 QUARTERLY INSPECTION ............................................................................................................................. 4-28

4-10 ANNUAL INSPECTION .................................................................................................................................. 4-28

4-11 RECOMMENDED HYDRAULIC OIL FOR HUSKY 12 PROPORTIONING SYSTEM .................................................. 4-28

4-11.1 CHARACTERISTICS ......................................................................................................................... 4-284-11.2 RECOMMENDATIONS ...................................................................................................................... 4-284-11.3 OIL CHANGE INFORMATION ............................................................................................................ 4-29

4-12 SYSTEM DIAGRAMS .................................................................................................................................... 4-30

INDEX

© 2012 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / iii

TABLE OF CONTENTS

iv / Husky 12 Foam System © 2012 Pierce Manufacturing Inc. All Rights Reserved.

FOREWORD

1. Purpose of Manual

The information in this manual is for the operation and maintenance of Pierce Husky 12 Proportioning System. It is intended to serve as a guide to assist qualified operators and mechanics in the operation and maintenance of their vehicle.

Keep this manual with the vehicle at all times.

NOTE: Some of the details of your vehicle’s design and construction may be unique to your department alone. For this reason, information contained in this manual may be generic at times. Questions on major inconsistencies between your vehicle’s configuration and the information contained in this manual should be directed to your Pierce Dealer or Sales Representative.

2. Scope

This supplemental operator’s manual provides operating and maintenance instructions for Husky 12 Proportioning Systems on vehicles manufactured by Pierce Manufacturing Inc.

This manual provides information under the following headings:

Safety. Contains important safety information, requirements before placing a vehicle in service, and information on installing custom equipment and accessories.

General. Includes information and instructions on the operation of major systems, controls, and indicators.

Operation. Contains procedures on performing common operations.

Maintenance. Contains scheduled preventive maintenance checks and inspections.

Appendixes. Contains information obtained directly from vendors who supply major components found on this unit.

3. Customer Assistance Information

Your satisfaction with your Pierce apparatus is important to your dealer and Pierce Manufacturing Inc. Normally, any question or concern you may have with your apparatus can be handled by your selling or servicing dealer. Your dealer has the facility, trained technicians, special tools, and up-to-date information to promptly address any issue that may arise. Pierce Manufacturing Inc. has empowered dealers to make decisions and repair vehicles, and they are eager to resolve your issues to your complete satisfaction. Should you encounter an issue with your Pierce apparatus that requires service, take the following steps:

Step 1.) Contact your authorized Pierce selling or servicing dealer. They will make the necessary arrangements to order the necessary parts and make the required repairs.

Step 2.) If they are not able to repair the problem to your satisfaction, discuss your concern with a member of dealer management. Normally, concerns can be quickly resolved at that level. If the matter has already been reviewed with the Sales, Service, or Parts Manager, contact the owner of the dealership or the General Manager.

Step 3.) If, after contacting a member of the dealership management, it appears your question or concern cannot be resolved by the dealership without further help, you may contact Pierce Manufacturing Inc. at 888-Y-PIERCE (888-974-3723).

© 2012 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / v

FOREWORD

vi / Husky 12 Foam System © 2012 Pierce Manufacturing Inc. All Rights Reserved.

© 2012 Pierce Manufacturing Inc. All Rights Re

SECTION 1
SAFETY
1-1. Introduction

1-1.1 To the Owner—Operation and Maintenance of This Apparatus

The information in this manual is for the operation and maintenance of this apparatus. The intent is to instruct operators in the proper operation of this equipment and to warn of improper procedures and potentially dangerous situations.

Only personnel who are totally familiar with this manual and have training are qualified to operate this apparatus. It is the responsibility of the department owning this equipment to permit only qualified personnel to operate this apparatus.

Qualified drivers of other fire apparatus will require further training for the handling of this unit.

1-1.2 Description of “DANGER,” “WARNING,” and “CAUTION”

THIS SAFETY SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL.

WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS THIS SYMBOL.

BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

Warning labels located on the vehicle and warning statements contained in this manual all use the same terminology to warn of potential hazards. Each of these potentially harmful conditions is described below:

The “signal words” of DANGER, WARNING, and CAUTION have specific meanings to alert you to the relative level or probability of the hazard.

Take the safety warnings seriously. If you do not understand them or have questions about them, contact Pierce Manufacturing Inc.

A hazard that will result in death or serious personal injury.

A hazard which might result in death or serious personal injury.

A hazard which might result in personal injury or damage to property or equipment.

served. Husky 12 Foam System / 1-1

SAFETY

1-2. List of Abbreviations

TERM DEFINITION

AFFF Aqueous Film Forming FoamAR-AFFF Alcohol Resistant Aqueous Film Forming Foam

FFFP Film Forming Fluoro-ProteinGPM Gallons per MinuteLCD Liquid Crystal DisplayLPM Liters per MinuteNFPA National Fire Protection AssociationPSI Pounds per Square Inch

RPM Revolutions per Minute

1-2 / Husky 12 Foam System © 2012 Pierce Manufacturing Inc. All Rights Reserved.


SECTION 2
GENERAL
2-1. Husky 12 Specifications

2-1.1 Foam Proportioner

The foam proportioning system is an on demand, automatic proportioning, single point, direct injection system suitable for all types of Class A & Class B foam concentrates, including the high viscosity (6000 cps), alcohol resistant Class B foams. The operation of the system is based on direct measurement of water flow, and remains consistent within the specified flows and pressures. The system automatically balances and proportions foam solution at rates from 0.1% to 9.9% regardless of variations in water pressure and flow, up to the maximum rated capacity of the foam concentrate pump.

The design of the system allows operation from draft, hydrant, or relay operation. This provides a versatile system to meet the demands at a fire scene.

2-1.2 System Capacity

The system has the ability to deliver the following (minimum) foam solution flow rates at accuracies that meet or exceed NFPA requirements at a pump rating of 250 PSI.

Table 2-1: Maximum Foam Solution Flow

The Class A foam setting is in .1% increments from .1% to 1%. Typical settings are .3% and .5%. *The maximum capacity is limited to the plumbing and water pump capacities.

2-1.3 Discharges

The number of discharges capable of dispensing foam varies from truck to truck, depending on customer specifications. Foam discharges can be identified by red/white tags; water only discharges can be identified by silver/black tags.

2-1.4 System Electrical Load

The electrical load for the foam proportioning system is less than five (5) amps at 12VDC.

2-1.5 Maintenance Message

A message is displayed on the control head to notify the operator when system maintenance needs to be performed. The message displays the interval for cleaning the foam strainer & water strainer, and changing the hydraulic oil. These messages will appear after 20 hours of foam system operation, if not reset during normal maintenance.

Concentration Percentage Capacity

6% 200 GPM3% 400 GPM1% 1,200 GPM .5% 2,400 GPM*.3% 4,000 GPM*


GENERAL

2-1.6 Flush System

A flush mode allows the system to flush all foam concentrate with clear water. The flush circuit control logic ensures the foam tank supply valve is closed prior to opening the flush valve. The flush valve is electrically controlled and is operated from the foam system control head. A manual flush drain valve is located under the driver’s side running board.

2-1.7 Foam Concentrate Compatibility

The Husky 12 Foam Proportioning System is designed to be compatible with most known Class A and Class B foam concentrates at the date of printing of this manual.

The Husky 12 can proportion foam concentrates across a wide range of viscosity, from low viscosities such as Class A or AFFF, through high viscosity AR-AFFF.

Table 2-2: Acceptable Foam Concentrate Viscosity Range

2-2. Description of Major Components

To understand the relationship of the various components and their functions, refer to Para 4-12., System Diagrams. The following information is intended to identify the various components and describe their function within the system. For specific construction, maintenance, and parts information, please refer to applicable service groups (chapters) in the service manual, drawings included in this manual, and the parts catalog for this unit.

2-2.1 Hydraulic Drive System

The hydraulic drive system that powers the foam pump is automatically activated when the water pump is engaged.

A hydraulic oil cooler prevents overheating of the hydraulic oil, which can be detrimental to system components. The oil/water cooler is designed to allow continuous system operation without allowing hydraulic oil temperature to exceed the oil specifications.

The system is delivered with ISO 68 hydraulic oil.

Acceptable Foam Concentrate Viscosity Range

Minimum 3 CentistokesMaximum 6000 Centipoise*

* Brookfield #3 Spindle @ 30 RPM


GENERAL

2-2.1a Hydraulic Gear Pump

Figure 2-1: Hydraulic Gear Pump

1001

The larger line is inlet from hydraulic tank; the smaller line is pressure line that drives the foam pump. The pump may be driven directly off Hale pump transmission, the Waterous impeller shaft, or a transmission-driven PTO (Chelsea) controlled by the pump engaged circuit #1659.

2-2.1b Hydraulic Oil Filter

Figure 2-2: Hydraulic Oil Filter

1002

The Hydraulic Filter is a pressure bypass element-type filter manufactured by Hydac. The filter element is replaceable. The unit is installed inside the pumphouse and is used to filter the pressurized hydraulic loop. The replacement part number for the filter element is Pierce P/N 1460998.

© 2012 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / 2-3

GENERAL

2-2.1c Hydraulic Oil Reservoir

Figure 2-3: Hydraulic Oil Cooler

1003

The Hydraulic Reservoir (approximately four gallon capacity) provides a reservoir for the hydraulic drive system. The tank is sufficient size to minimize foaming of the hydraulic fluid and is located to facilitate checking level and adding oil. Refer to Para 4-11., Recommended Hydraulic Oil for Husky 12 Proportioning System, for recommended hydraulic oil for the Husky 12 system.

2-2.1d Hydraulic Oil Cooler

Figure 2-4: Hydraulic Oil Cooler

1004

To Hydraulic Pump

Shut-off Valve (in-line position is OPEN)

Hydraulic Oil In/Out

Cooling Water In/Out


GENERAL

The Hydraulic Cooler is an oil-to-water type heat exchanger. It takes water directly from the water pump to cool the closed loop hydraulic system. The cooling water is then returned to the water pump suction while the cooled hydraulic oil is returned to the hydraulic tank. The hydraulic cooler allows for continual operation of the Husky 12 hydraulic system.

2-2.1e Hydraulic Manifold Block

Figure 2-5: Hydraulic Manifold Block

1005

The Hydraulic Manifold Block assembly is a manifold block that controls the direction of the hydraulic oil flow in the system. The manifold block consists of the machined block, a hydraulic compensating valve, an internal hydraulic shuttle valve, a hydraulic relief valve, hydraulic pressure test port and the hydraulic proportional valve.

2-2.2 Foam Supply System

The Foam Supply System stores, pumps and distributes the foam concentrate to the foam/water discharges by use of a foam concentrate tank, foam tank shut-off valve, auxiliary foam inlet, in-line foam strainer, foam pump, check valve and foam injection manifold.

2-2.2a Foam Concentrate Tank

The Foam Concentrate Tank is designed to provide on-board storage of foam concentrate. Design features shall include: construction compatible with foam concentrates, foam tank drain valve, expansion dome with locking fill hatch and pressure/vacuum vent. The expansion dome allows for changes in foam concentrate volume due to variations in temperature. Foam concentrate level shall be maintained at the one-third full mark in the expansion dome at a minimum to reduce the air to foam concentrate interface. The pressure vacuum vent automatically balances internal foam tank pressure under both suction and filling operations. It is recommended that a cleanable foam concentrate level unit be installed in the storage tank. The control head will display a warning message when the foam tank being used is below one quarter tank.

Forward Plug

Hydraulic Relief Valve

Reverse Plug

Not shown: P1 pressure test port (on side of

hydraulic block)


GENERAL

2-2.2b Foam Supply Valve

Figure 2-6: Foam Supply Valve

1006/1007

An electric/air valve is used for the Foam Supply Valve. The foam supply valve shall be controlled at the foam system control head for ease of operation. The supply valve is located to eliminate air pockets in the foam tank supply hose. This foam supply valve opens automatically when the system is turned ON.

2-2.2c Foam Concentrate Pump

Figure 2-7: Foam Concentrate Pump

1008

The Foam Concentrate Pump assembly is a brass/steel constructed, double-acting cylinder pump. The hydraulic end of the pump is painted steel and controls the speed and direction of both cylinders. The hydraulic piston is connected to the foam piston by a single, straight shaft. The foam end of the pump is brass construction and contains 4 cartridge type check valves to prevent foam from flowing the wrong direction in the pump.


GENERAL

The foam pump also has a pressure relief valve that recirculates the foam from the discharge side to the inlet side in the case of an obstruction or overpressure situation. The foam pump speed and operation are monitored by a foam pump transducer located in the hydraulic end of the pump assembly.

The foam concentrate pump is self-priming and has the capability to draw foam concentrate from external supplies such as drums or pails. The foam concentrate pump has a maximum capacity of 12 GPM with all types of foam concentrates with a viscosity at or below 6000 cps including protein, fluoroprotein, AFFF, FFFP, or AR-AFFF.

2-2.2d Foam Selector Valve

Figure 2-8: Foam Selector Valve

1009

The Foam Selector Valve is a 2-way, quarter-turn ball valve that directs the foam for foam injection (normal operation) or tank filling. A “CHECK SELECTOR VALVE” message is displayed by the control head in the event that the valve is not in the correct position for the operation selected.

From Foam Pump

Tank Fill Hose*

Injection Hose

*A foam selector valve with the tank fill option is shown. On units without the tank fill option, the fill

hose will be routed directly to tank.


GENERAL

2-2.2e Panel Mounted Strainer / External Pick-Up Connection

Figure 2-9: Panel Mounted Strainer / External Pick-Up Connection

1010

A bronze body strainer / connector unit is mounted on the pump panel. The external foam pick-up consists of one (1) 1 in. male connection with chrome-plated cap, integrated to a 2 in. strainer clean-out cap. A check valve is installed in the pick-up portion of the clean-out cap. A basket style stainless steel screen is installed in the body of the strainer / connector unit.

The strainer is used to prevent any debris from entering the foam system and possibly interfering with the internal foam pump check valves.

Removal of the 2 in. clean-out cap is all that is required to gain access to and remove the stainless steel basket screen. The strainer / connector is located ahead of the foam concentrate pump inlet port, to insure that all agent reaching the foam pump has been strained.

The external foam pick-up permits the use of a foam agent that is not stored on the vehicle. The external foam pick-up also allows continued operation after the on-board foam tank is empty. The external foam pick-up can also be used with training foam or colored water for training purposes.

This connection also functions as the Class A tank fill (when equipped with tank fill option) and as the foam tank drain.


GENERAL

2-2.2f Pick-Up Hose

Figure 2-10: Pick-up Hose

1012

A 1 in. flexible hose, with an end for insertion into foam containers, is provided. The hose has a 1 in. female swivel NST thread swivel connector. (The hose is part of loose equipment.)

2-2.2g Foam Check Valve

Figure 2-11: Foam Check Valve

1013

The Foam Check Valve located in the foam supply line prevents water from flowing backwards through the foam system and contaminating the foam supply.

2-2.3 Water Supply System

The water supply system supplies water to the foam injection manifold for foam to be added and distributed to the foam/water discharges. This system consists of an in-line water check valve, water flowmeter and flowmeter installation tee. The size of the check valve and the flowmeter installation tee are dependent on the number of foam/water discharges in the system.


GENERAL

2-2.3a Manifold and Master Drains

Figure 2-12: Manifold & Master Drains

1066/1067

The manifold drains are used to bleed off pressure/water anytime the water pump has been pressurized (after the water pump is shut off). If a dry water pump condition is desired, leave manifold drains open until the fire scene is reached.

The master pump drain will empty both the discharge and inlet manifolds of water when opened. The water pump drain should be pulled (opened) daily.

2-2.3b In-line Water Check Valve

Figure 2-13: In-line Water Check Valve

1014

The In-line Water Check Valve prevents foam from entering the water pump and the remainder of the water system. It is installed in the water piping, before the foam injection manifold and the water flowmeter.


GENERAL

2-2.3c Water Flowmeter

Figure 2-14: Water Flowmeter

1015

The Water Flowmeter measures the flow of water supplied to the foam/water discharges before foam is injected. This controls the amount of foam that is injected when the Husky 12 foam system is turned on.

2-2.4 Control System

The control head directs a microprocessor, which receives input from the system’s water flowmeter while also monitoring the position of the foam concentrate pump. The microprocessor compares the values of the water flow versus the position/rate of the foam pump, to ensure the proportion rate is accurate.

2-2.4a Controller Module

Figure 2-15: Controller Module

1016


GENERAL

The foam system is controlled by a foam system controller module that contains the programming to actuate the appropriate valves, direct the hydraulic fluid, and control the injection rate of the foam. All components plug into the Foam Module. The foam module is what actually controls the system. The user interfaces with the controller through the foam system control head. If replaced, the system calibration must be checked.

2-2.4b Control Head

Figure 2-16: Control Head

1000

The Foam System Control Head is the operator interface with the foam system. It is located on the main pump panel. It has six operating buttons: System On/Off, Mode, Display, Enter, Arrow Up, Arrow Down. The display is a 2-line, 32 character, LCD screen. System power is indicated by a red LED; the foam pump operating is indicated by a green LED.

Information displayed on the LCD screen includes: mode of operation and various information displays. If the foam system is turned OFF, the display functions as a flowmeter.

The percent of injection has presets for class A and class B foam. These presets can be changed at the fire department as desired. The percent of injection can be easily changed at the scene to adjust for changing demands.

The modes of operation are: Class A Foam, Class B Foam (optional), Draft Class A, Draft Class B, Prime, Flush, Tank A Fill (optional), Tank B Fill (optional), Manual, and Set-up. Pressing the MODE button on the display head changes from one mode to the next. Detailed instructions on the operation of each mode can be found in Section 3, “Operation”.


GENERAL

Figure 2-17: Control Head Display Modes

1030

The information displays are: GPM (used for most operations), Foam Type & Flow Rate, Total Water Flowed, Total Class A usage, and Total Class B usage. Pressing the DISPLAY button on the display head changes from one display view to the next.

Figure 2-18: Resetting Control Head Counters to Zero

1075

Display counters and default settings will automatically reset by cycling the batteries after operation.

All of the display screens may be zeroed during operation by pushing the ARROW UP/ARROW DOWN buttons at the same time then releasing.


GENERAL



SECTION 3
OPERATION
3-1. Foam System Operation

3-1.1 Class A Foam - using on-board Foam Tank

Figure 3-1: Control Head in Class A Foam Mode

1017

1. Engage water pump transmission.

2. Recirculate water.

3. Turn the system ON.

NOTE: The default foam valve will open automatically (typically Class A, @ 0.3-.5%).

4. Begin flowing water, foam pump will activate.

5. Use the ARROW UP / ARROW DOWN buttons to change percentage (if needed).

6. When beginning the mop up phase, turn the system OFF; use the foam in the hose for mop up.

NOTE: The only flush needed is to run the hose until it is mostly free of bubbles. The foam pump is designed to be flooded with foam


OPERATION

3-1.2 Class A Foam - Drafting

Figure 3-2: Control Head in Class A Drafting Mode

1018

1. Set up for drafting operation by positioning foam and hooking up pick-up hose.

2. Press MODE until the DRAFT CLASS A screen appears, then press ENTER. On-board tank valves will close, causing suction to draw from foam inlet.

3. The default percentage will remain the same as the on-board Class A tank current setting.


5. See Para 3-2.1, General Flushing Information.

3-1.3 Class B Foam - using on-board Foam Tank

Figure 3-3: Control Head in Class B Foam Mode

1019

NOTE: This operation is only possible when the Class B foam tank is installed and enabled.

1. Press MODE until the CLASS B FOAM screen appears, then press ENTER. The Class A foam valve will close; an automatic flush will occur prior to the Class B valve opening, provided the water flow meter senses water flow.



During the automatic flush, water must be flowing through an open foam discharge OR open manifold drain to give the flush solution somewhere to go.


OPERATION

3-1.4 Class B Foam - Drafting

Figure 3-4: Control Head in Class B Drafting Mode

1020

1. Set up for drafting operation by positioning foam and hooking up pick-up hose.

2. Press MODE until the DRAFT CLASS B screen appears, then press ENTER. On-board tank valves will close, causing suction to draw from foam inlet.

NOTE: An automatic pre-programmed flush of 10-15 seconds will occur when changing from Class A to Class B foam, once the water flow meter senses water flow.

3. The default percentage will remain the same as the on-board Class B tank current setting.



3-2. Flushing System

3-2.1 General Flushing Information

NOTE: For the purposes of this manual, it is assumed that Class A foam is the most commonly used agent and that the system will be stored wet with Class A foam concentrate. If Class A foam is not the primary agent, adjust procedures to accommodate the primary foam concentrate.

Typically, no flushing is needed. The Husky 12 foam pump is designed to be flooded with foam. Unless the optional Class B foam tank was used, a different brand of Class A foam was drafted, or Class B foam was drafted, the only system flush that is needed is to turn the system OFF and continue flowing water until the presence of bubbles is minimal.

When beginning mop-up operations at the scene, turn the system OFF and use the foam in the hose for mop-up.

When equipped with two on-board foam tanks (Class A & Class B), an automatic flush will occur for 10-15 seconds when switching between the two tanks. A foam discharge or manifold drain must be open during the automatic flush to give the flush solution somewhere to go.

This automatic flush time can be adjusted in the set-up mode, refer to Para 4-2.15, Reset Maintenance Reminders for instructions. In addition to the automatic flush, it is recommended to do an additional manual flush to ensure the system is completely free of contaminates.


OPERATION

3-2.2 Manual Flush Mode

Figure 3-5: Control Head in Flush Mode

1021

NOTE: The Manual Flush Mode is only for use when additional flush time is desired, such as after switching between types and / or brands of foam.

1. Continue flowing water out the discharges that were used.

2. Open both foam pump drains and manifold drain.

3. Press MODE until the FLUSH MODE screen appears, then press ENTER. This enters the flush mode.

4. Press and hold the ENTER button (a second time). This will run the foam pump at 7 GPM until the button is released. Continue to hold until foam pump drains and manifold drains run clear.

3-2.3 Flushing After Drafting Class A Foam

1. If the same type and brand of foam as in the on-board tank was used:

a. Turn the system OFF and flow water through the discharges that were used until the presence of bubbles is minimal.

2. If a different type or brand of foam as in the on-board tank was used, or if you are uncertain:

a. Continue flowing though all foam discharges that were used.

b. Disconnect the pick-up hose and reinstall cap. Rinse pick-up hose with clean water when possible.

c. Open the foam pump and manifold drains.

d. Press the MODE button until CLASS A FOAM appears, then press ENTER.

e. Press the MODE button until FLUSH MODE appears, then press ENTER, release, and hold for 1-2 minutes or until foam pump and manifold drains run clear.

f. Close foam pump drains continue flowing water though one discharge.

g. Press the MODE button until PRIME appears; then press ENTER for 5-10 seconds or when bubbles show up at the manifold drain.

h. Turn off the foam system, flow water through the discharge until the presence of bubbles is minimal. It is now primed for the next call.

Water must be flowing through an open foam discharge OR open manifold drain to give the flush solution somewhere to go.


OPERATION

3-2.4 Flushing After Drafting Class B Foam

1. Continue flowing though all foam discharges that were used.

2. Disconnect the pick-up hose and reinstall cap. Rinse pick-up hose with clean water when possible.

3. Open the foam pump and manifold drains.

4. Press the MODE button until CLASS A FOAM appears, then press ENTER. (Automatic flush will occur when changing from B to A).

5. Press the MODE button until FLUSH MODE appears, then press ENTER, release, and hold for 1-2 minutes or until foam pump and manifold drains run clear.

6. Close foam pump drains continue flowing water though one discharge.

7. Press the MODE button until PRIME appears; then press ENTER for 5-10 seconds or when bubbles show up at the manifold drain.

8. Turn off the foam system, flow water through the discharge until the presence of bubbles is minimal. It is now primed for the next call.

3-3. Priming System

Figure 3-6: Control Head in Prime Mode

1022

The Prime Mode is used to accelerate the foam pump for a short period of time, such as to purge the air out of the on-board tank lines after initial filling or to fill the suction hose while drafting.

1. Select foam source.

NOTE: Perform Step 2 thru Step 6 if the Husky 12 Foam System is installed on a Pierce Ultimate Configuration (PUC) apparatus, otherwise skip to Step 7.

2. Open foam pump discharge drain.

3. Press MODE until the PRIME MODE screen appears, then press ENTER. This enters the prime mode.

Water must be flowing through an open foam discharge OR open foam pump discharge drain to give the foam solution somewhere to go.


OPERATION

4. Press and hold the ENTER button (a second time). This will run the foam pump at 7 GPM until the button is released.

5. Release the button when foam is discharged out of the foam pump discharge drain.

6. Close the foam pump discharge drain.

7. Open manifold drain.

8. Press MODE until the PRIME MODE screen appears, then press ENTER. This enters the prime mode.

9. Press and hold the ENTER button (a second time). This will run the foam pump at 7 GPM until the button is released.

10. Release the button when foam is discharged out of the manifold drain.

11. Allow water/foam solution to run out of manifold drain until it is mostly clear of foam if unit is not immediately going to be used to fight fire.

12. Close the manifold drain.

Water must be flowing through an open foam discharge OR open manifold drain to give the foam solution somewhere to go.


OPERATION

3-4. Filling Foam Tank(s)

NOTE: For the purposes of this manual, it is assumed that Class A foam is the most commonly used agent and that the system will be stored wet with Class A foam concentrate. If Class A foam is not the primary agent, adjust procedures to accommodate the primary foam concentrate.

3-4.1 Class A Tank Fill (Optional)

Figure 3-7: Control Head in Class A Tank Fill Mode

1023/1072

1. Engage water pump to activate hydraulics and recirculate water.

2. Turn system ON.

3. Attach pick-up hose to foam pump inlet.

Figure 3-8: Selector Valve

1024/1025

Do not mix different types or manufacturer’s brands of foam concentrate in the foam cells or piping. Mixing of different foam concentrates (either type or manufacturer) may cause deterioration of the foam concentrate, improper proportioning, and poor performance in a fire situation. Mixing of Class A and Class B foam concentrates may result in a chemical reaction that can create globules, which can clog orifices and cause system failure.

Foam Inject Position Tank Fill Position


OPERATION

4. Press MODE until the TANK A FILL screen appears. Press ENTER.

NOTE: • CHECK SELECTOR VALVE will appear on the control head if the selector valve is not in the correct position to fill tank.

• The float switch in foam tank dome will automatically stop the fill process.

5. Turn the selector valve to the TANK FILL position.

NOTE: TANK A FULL will briefly appear on the control head when the fill cycle is complete and then switch to CHECK SELECTOR VALVE. The system will automatically stop the tank fill cycle and return to normal operation.

6. Return selector to the INJECT MODE position.

3-4.2 Class B Tank Fill (Optional)

Figure 3-9: Control Head in Class B Tank Fill Mode

1026

1. Start engine or attach external air supply to chassis.

2. Attach pick-up hose to Foam B refill (this inlet fills Tank B only).

3. Open Foam B Refill valve.

NOTE: TANK B FULL will appear on the control head when the fill cycle is complete. The system will automatically stop the tank fill cycle and return to normal operation.

4. Press MODE until the TANK B FILL screen appears. Press ENTER.


OPERATION

3-4.3 Fill through Foam Tank Fill Dome

NOTE: Locate and close all foam tank and manifold drains. They may be found on and behind both the driver and passenger side pump panels.

When filling the foam concentrate during a non-fire situation, the following procedure is recommended:

1. The vehicle should be parked on a level surface or with the expansion dome of the tank slightly inclined.

2. If filling from a pressurized source through the expansion dome hatch, the hose should be extended to the bottom of the tank to minimize frothing of the foam concentrate.

3. If foam concentrate must be added by pouring through the expansion dome hatch, it must be done slowly to prevent aeration. If aeration occurs inside the tank, stop pouring until the foam concentrate bubbles dissolve. Take care not to allow dirt or debris to enter the tank. Pour the foam concentrate down the center of the round tube when filling the tank. This tube goes into the tank and allows the foam concentrate to enter under the surface of foam currently in the tank to reduce aeration of the foam per NFPA.

3-5. Manual Mode

This mode of operation is the NFPA required manual override. This mode is used to activate the foam pump without the flowmeter operating.

Do not mix different types or manufacturers brands of foam concentrate in the foam cells or piping. Mixing of different foam concentrates (either type or manufacturer) may cause deterioration of the foam concentrate, improper proportioning and poor performance in a fire situation. Mixing of Class A and Class B foam concentrates may result in a chemical reaction that can create globules, which can clog orifices and cause system failure.


OPERATION

Figure 3-10: Control Head in Manual Mode

1027

1. Press MODE until the MANUAL MODE screen appears, then press ENTER. This enters the manual mode.

2. Press and hold the ARROW UP / ARROW DOWN buttons until the estimated flow is reached.

3. Press ENTER; the foam pump will run.

4. Monitor and adjust for estimated water flow rate changes.

IMPORTANT: The foam flow rate will remain constant, even when actual water flow fluctuates.

5. Turn foam pump OFF to stop foam flow.

NOTE: An alternate method would be to set the GPM to a fixed rate and adjust the percentage of foam.

3-5.1 Flowmeter Operation

Figure 3-11: Control Head in Flowmeter Mode

1028

In this mode, the foam pump will run regardless of water flow. If discharges are closed, these lines may be charged to over 300 PSI. At least one discharge or manifold drain must be open before entering this mode.


OPERATION

This operation returns the system to (normal) flowmeter control and only appears when in manual mode.

1. Press MODE until the USE FLOWMETER screen appears, then press ENTER. This enters the flowmeter mode.

3-6. Set-up Mode

Refer to Para 4-2.1, Set-up Mode for Set-up Mode information.


OPERATION



SECTION 4
MAINTENANCE
4-1. Maintenance Introduction

This section of the manual has been prepared to help keep your equipment in good operating condition and ready for its primary mission.

The procedures and recommended intervals in this section are based on normal operating conditions and may have to be modified to meet the existing conditions. Some environmental concerns may dictate that inspection and maintenance be performed at more frequent intervals.

For various proportioning system components (water pump, discharge devices, valves, actuators, etc.), refer to that particular component’s Operation and Maintenance Manual or Service Manual Group (chapter).

4-1.1 Testing After System Maintenance

If during the course of normal system maintenance it becomes necessary to replace, repair, or modify system components, component parts, operating devices or equipment, the system must be tested to ensure proper operation before being placed back into service.

The services of a qualified field engineer to inspect the system, run the tests for start-up, and the annual inspection can be provided. Additional details can be obtained by contacting Pierce Manufacturing.

1. Draining Foam Pump After Testing

a. Open all drains. Remove foam inlet cap. If equipped, turn the selector valve to the middle position (halfway between TANK FILL and INJECT). Cycle foam tank valves as needed until tanks and lines are empty. Reinstall inlet cap.

b. After moving truck to its destination, cycle the foam tank valves again to get any residual water out of the lines.

2. Blowing Out After Testing

a. After blowing out the main water pump, cycle through and operate the flush mode with air.

b. Attach shop air (90 psi or less) directly to the inlet. Run the foam pump through a couple of cycles to get the water out.

c. If equipped, run air through the tank fill options.

d. After moving truck to its destination, cycle the foam tank valves again to get any residual water out of the lines.

If, for any reason, the hydraulic reservoir shutoff valve is ever in the closed position, the hydraulic pump should be de-coupled from the water pump or the truck must be taken out of service. Failure to do so will result in severe damage to the hydraulic pump.

During cold weather, the foam system must be blown out after testing with water. Water cannot remain in the foam system after testing. Either fill the foam system with foam concentrate or blow out the foam system with compressed air using the following procedure. Failure to comply may result in the water freezing and damaging foam system components.


MAINTENANCE

4-2. Set-up & Calibration

Set-up Mode is used to access calibration modes, change default settings and access foam tank drain mode. The functions are shown in this chapter in the order they appear on the control head LCD screen.

4-2.1 Set-up Mode

Figure 4-1: Set-up Screen

1031

3. Press MODE button until display reads:

4. Press ENTER / ARROW UP / ARROW DOWN at the same time to enter the Set Up Mode screens.

5. Press MODE to scroll through the Set Up Mode screens.

6. Follow the prompts on the screen

4-2.2 English/Metric Mode

Figure 4-2: English/Metric Screen

1032

NOTE: The English/Metric screen provides the option of reading the flow in GPM or LPM.

1. Press MODE until the DEFAULT SYSTEM screen appears, then press ENTER

2. Press ARROW UP or ARROW DOWN to toggle between the two options.

3. Press ENTER again to store the new default setting.

Set-up and Calibration Modes should only be used by qualified personnel, as any changes made while in the Set-up or Calibration Modes may adversely affect the system performance.


MAINTENANCE

4-2.3 Calibrate Flowmeter Mode

Figure 4-3: Calibrate Flowmeter Screens

1033/1035/1165/1166

NOTE: Calibrate Flowmeter Mode is used to calibrate the water flowmeter.

IMPORTANT: Before calibrating, verify the water flow using a pitot tube. If the flow is correct at various flow rates, based on the pitot tube results, no calibration is needed.

1. While in the Set Up Mode screens, press MODE button until display reads CALIBRATE FLOWMETER MODE, then press ENTER.

NOTE: If unable to flow the default flow rates, different flow rates may be obtained by pressing ARROW UP or ARROW DOWN in order to achieve different flow rates other than the default settings. The wider the rates are during calibration, the more accurate the flowmeter will be over those flow rates.

2. Attach the appropriate hose(s) and nozzle(s) to one or more foam/water discharge(s) to obtain a known water flow of 50 GPM (low gpm flow meter setting). Open the discharge valve(s).

3. At the CAL FLOWMETER 50 GPM screen, press ENTER. RUNNING CALIBRATION will show on the LCD display until the first calibration set point is complete.

4. CAL FLOWMETER 300 GPM will automatically appear next.

5. Attach the appropriate hose(s) and nozzle(s) to one or more foam/water discharge(s) to obtain a known water flow of 300 GPM (high gpm flow meter setting). Open the discharge valve(s).

6. Press ENTER to begin calibration. RUNNING CALIBRATION will again appear.

7. When calibration is complete, press MODE to exit Set-up Mode.

8. Confirm accuracy by flowing various flow rates.

4-2.4 Calibrate Foam Pump (LVDT) Transducer

Figure 4-4: Foam Pump Transducer Calibration Screen

1037

NOTE: The foam pump transducer must be calibrated before performing any other foam system calibration procedures.

1. While in the Set-up Mode, press MODE button until display reads CALIBRATE FOAM PUMP TRANSDUCER.


MAINTENANCE

2. Press ENTER to begin calibration.

Figure 4-5: Foam Pump Transducer Voltage Screen

1152

3. While the calibration is running, the display will indicate LVDT voltages at each end of the foam pump stroke. The normal voltage reading is 0.3v - 0.7v (left) and 4.3v - 4.8v (right).

4. When the calibration is complete, the display will again read CALIBRATE FOAM PUMP TRANSDUCER.

4-2.5 Calibrate Class A Foam Mode

Figure 4-6: Calibrate Class A Screen

1038

NOTE: • Prior to calibrating, run the system at different rates and verify that it is in need of calibration.

• The most accurate calibration can be obtained using the actual foam concentrate intended for use at a fire incident. However, if foam is unable to be used, water is an acceptable substitute.

• Verify that the draft hose is securely installed, the Foam Inlet Valve is OPEN, the Foam Pump is primed, and the foam source is set to DRAFT CLASS A before beginning foam calibration.

1. While in the Set-up Mode, press MODE button until display reads CALIBRATE MODE CLASS A FOAM.

2. Press ENTER to accept. Display should read CALIBRATE FOAM A (or B) 1.00 GPM

3. Press ENTER to begin foam calibration at 1.00 GPM. The foam pump will run for five minutes.

4. Measure actual flow by measuring the foam/water pick-up through draft hose.

5. When green Foam Pump ON light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. (In this example “1.1”)

6. Press ENTER to accept value.

7. Display should read: CALIBRATE FOAM A 4.00 GPM

8. Press ENTER to begin foam calibration at 4.00 GPM. Foam pump will run for five minutes.

9. Measure actual flow by measuring the foam/water pick-up through draft hose

10. When green “Foam Pump On” light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed.


12. Display should read CALIBRATE MODE CLASS A FOAM.


MAINTENANCE

13. Press MODE to exit Set-up Mode.

4-2.6 Calibrate Class B Foam Mode

Figure 4-7: Calibrate Class B Screen

1039

NOTE: • Prior to calibrating, run the system at different rates and verify that it is in need of calibration.

• The most accurate calibration can be obtained using the actual foam concentrate intended for use at a fire incident. However, if foam is unable to be used, water is an acceptable substitute.

• Verify that the draft hose is securely installed, the Foam Inlet Valve is OPEN, the Foam Pump is primed, and the foam source is set to DRAFT CLASS B before beginning foam calibration.

1. While in the Set-up Mode, press MODE button until display reads CALIBRATE MODE CLASS B FOAM.

2. Press ENTER to accept. Display should read CALIBRATE FOAM B 1.00 GPM

3. Press ENTER to begin foam calibration at 1.00 GPM. The foam pump will run for five minutes.

4. Measure actual flow by measuring the foam/water pick-up through draft hose.

5. When green Foam Pump ON light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed. (In this example “1.1”)


7. Display should read: CALIBRATE FOAM B 4.00 GPM

8. Press ENTER to begin foam calibration at 4.00 GPM. Foam pump will run for five minutes.

9. Measure actual flow by measuring the foam/water pick-up through draft hose

10. When green “Foam Pump On” light turns off, measure the actual amount of foam concentrate flowed. Calculate the gallons per minute (GPM) used during the five minutes. (Example: 5.5 gallons flowed divided by 5 minutes = 1.1 GPM.) Using the ARROW UP or ARROW DOWN buttons, enter the GPM flowed.


12. Display should read CALIBRATE MODE CLASS B FOAM.

13. Press MODE to exit Set-up Mode.

4-2.7 Set Class A Concentrate Default Percentage

Figure 4-8: Class A Default Screen

1040


MAINTENANCE

NOTE: The default percentage is set at the factory to automatically run at 0.5% for Class A foam. Temporary changes to the foam percentage may be made while running the system by using the ARROW UP or ARROW DOWN buttons. The department may find it beneficial to change the defaults for their particular operating requirements or different types or brands of foam.

1. While in the Set-up Mode, press MODE button until display reads CLASS A DEFAULT, then press ENTER.

2. Press ARROW UP or ARROW DOWN to adjust default to the desired rate.

3. Press ENTER to accept new default rate.

4. Cycle batteries to confirm changes.

4-2.8 Set Class B Concentrate Default Percentage

Figure 4-9: Class B Default Screen

1041

NOTE: The default percentage is set at the factory to automatically run at 3.0% for class B foam. Temporary changes to the foam percentage may be made while running the system by using the ARROW UP or ARROW DOWN buttons. The department may find it beneficial to change the defaults for their particular operating requirements or different types or brands of foam.

1. While in the Set-up Mode, press MODE button until display reads CLASS B DEFAULT, then press ENTER.

2. Press ARROW UP or ARROW DOWN to adjust default to the desired rate.

3. Press ENTER to accept new default rate.

4. Cycle batteries to confirm changes.

4-2.9 Select Single or Dual Foam Tank System

Figure 4-10: Tank Option Screens

1042/1043

NOTE: In the set up mode there is a screen that allows the software to recognize that the truck has been configured with one or two foam tanks. If the single/dual tank selection is not correct, the system may not run as it is “searching” for the second tank valve that is not installed, or it may not recognize the alternate foam valve is there because it was set for a single tank system.

1. While in the Set-up Mode, press MODE button until the Tank Option screen appears, then press ENTER.

2. Press ARROW UP or ARROW DOWN to toggle between single and dual tank options.

3. Press ENTER to accept the selection.


MAINTENANCE

4-2.10 Set Default Foam Source

Figure 4-11: Default Foam Source Screens

1044/1045

NOTE: The default foam source setting is used to determine which tank will open as the default tank, Class A or Class B. On a single tank system it will change the default setting (Class A or Class B). If changing a single tank system from A to B default, the foam valve remains plugged into the Class A harness. If changing the types of foam in the tank, It is imperative to thoroughly flush out and dry the entire system.

1. While in the Set-up Mode, press MODE button until the Default Tank screen appears, then press ENTER.

2. Press ARROW UP or ARROW DOWN to toggle between DEFAULT TANK A and DEFAULT TANK B options.


4-2.11 Tank Fill Enable/Disable

Figure 4-12: Tank Fill Option Screens

1046/1047

NOTE: The tank fill option must be enabled in order for the option to work. In order for the option to work, the system must have the optional tank fill valve installed for a single tank system, the air diaphragm fill pump for dual tank systems, and shut off floats installed in the tank dome to actuate the automatic shutoff when the tank is full.

1. While in the Set-up Mode, press MODE button until the Tank Fill screen appears, then press ENTER.

2. Press ARROW UP or ARROW DOWN to toggle between DISABLED and ENABLED options.



MAINTENANCE

4-2.12 Set Automatic Flush Time

Figure 4-13: Flush Time Screen

1048

NOTE: • An automatic flush occurs whenever foam source is switched from a Class A to Class B foam or vice-versa.

• The factory default setting is 10-15 seconds.

1. While in the Set Up Mode screens, press MODE button until the Flush Time screen appears, then press ENTER.

2. Press ENTER to accept.

3. Press Arrow Up or Arrow Down to change the flush time value.

4. Press ENTER to accept new default value.

4-2.13 Auto Start

Figure 4-14: Auto Start Screens

1049/1050

NOTE: The auto start option will automatically turn the foam system on the first time the water pump is engaged. The option must have sensors installed in the foam system hydraulics and have additional wiring installed in order to function.

1. While in the Set-up Mode, press MODE button until the Auto Start screen appears, then press ENTER.

2. Press ARROW UP or ARROW DOWN to toggle between DISABLED and ENABLED options.



MAINTENANCE

4-2.14 Drain Mode

Figure 4-15: Control Head in Drain Mode

1051/1052

NOTE: The Foam Drain mode is used to drain the foam tanks when needed.

1. While in the Set-up Mode, press MODE button until the Drain Mode screen appears.

2. Press ENTER - this will close any tank valve that is open.

Figure 4-16: Inlet Cap with Check Valve

1069

NOTE: The inlet cap contains a check valve; the drain cap does not have a check valve.

3. Remove the inlet cap, install drain cap, and attach hose - have container available.

4. Select the tank on dual tank systems.

5. PRESS UP TO DRAIN AND DOWN TO STOP message will appear.

6. Pushing ARROW UP will open the drain valve; pushing ARROW DOWN will close the drain valve. Use the buttons as needed when changing containers

7. To exit screen, turn the system OFF.


MAINTENANCE

4-2.15 Reset Maintenance Reminders

Figure 4-17: Maintenance Reminder Screens

1053-1056

NOTE: • Maintenance messages flash alternately with main operating screen after 20 hours of foam system operation

• Separate screens allow user to reset the counters for strainer and fluid service reminders

• If these messages occur in the station, have service performed.

• If these messages occur on the scene, verify the hydraulic oil level, continue operation, and have service performed upon returning to the station.

1. While in the Set Up Mode screens, press MODE button until one of the reset screens appears.

2. Press ENTER to reset counter. When counter has been reset, display will read COUNTER RESET.

4-2.16 Check Current Software Revision

Figure 4-18: Control Head showing Software Revision

1057

NOTE: This information is also displayed when the system is first turned ON.

While in the Set Up Mode screens, press MODE button until the Software Revision screen appears.


MAINTENANCE

4-3. Troubleshooting

The following outline represents operational difficulties that may arise during the deployment of the unit. It is not a comprehensive list meant to exhaust every possible malfunction of the equipment. Rather it is a quick checklist to allow operating personnel to ensure that operator error is not preventing the safe deployment of the unit.

Table 4-1: General Troubleshooting

Symptom Possible Cause Corrective Action

1. LCD on control head is blank or displaying random characters. Red light comes on.

Bad control head. • Replace control head.

Wiring issue. • Check the ground circuit, ckt# 1640, pin 2.

• Check the voltage at the battery.

• Check the voltage at the control head, ckt# 2878, pin 1. Voltage at the control head should be within .2 volt of the battery voltage.

2. LCD on control head is blank and foam system will not turn on.

Wiring issue. • Check the ground circuit, ckt# 1640, pin 2.


Bad control head (check for red light on).


Check for bad foam controller (check for flashing green light which indicates a good heart beat).

• Check the single point ground. If red light is not on, replace control head. If green light is not flashing, replace foam controller.

3. System does not accurately display the amount of foam used.

LVDT or water flow meter out of calibration.

• Recalibrate LVDT and water flow meter.

Incorrect software version. • Contact Pierce for latest software version.

4. System is using excessive foam.

LVDT or water flow meter out of calibration.

• Recalibrate LVDT and water flow meter.

Wrong software version. • Contact Pierce for latest software version.

Inspect the check valve at the injection fitting.

• Foam should not leak past the injection fitting check valve with system OFF. If fitting leaks, replace.


MAINTENANCE

5. Delay before getting foam from hand line.

Wrong software version. • Contact Pierce for latest software version.

Needless flushing of system and not recharging.

• See Chapter 3, Operating Procedures.

System not turned on before charging line.

• Turn on system at pump panel as first step in operation.

6. Foam in water tank after using foam system.

Hand lines not flushed. • Flush hand lines.

Defective flush valve. • Replace flush valve.

UPF tank issue. • Fill foam tank; add florescent dye. Let unit sit overnight. Check the water tank to see if the florescent color is present in the water. If so, the foam tank is cracked.

Bad manifold check valve. • If foam manifold bleeds down rapidly, replace or disassemble/clean check valve. It is normal for the manifold to bleed down slowly.

Bad foam injection check valve. • Foam should not leak past the injection check valve with system OFF. If fitting leaks, replace.

Manifold drain not bled down. • Manifold drain should be used after each use.

7. Foam tank empty after pumping operation with foam system turned off.

Bad check valve for foam tank fill. • Check selector valve for being in INJECTION mode.

Bad foam injection check valve. • Check injection check valve to see if foam leaks by.

Bad tank to pump valve. • Check tank to pump valve.

8. System will not draft foam. • See Table TBD, System Will Not Pump Foam from Foam Tank

9. Tank fill inoperable. Selector valve in wrong mode. • Check tank fill/injection switch at selector valve for being in TANK FILL position.

Tank to pump valve did not close. • Check tank to pump valve and the switch on the valve.

Float stuck full (false reading). • Check float.

Tank fill check valve does not open. • Check to see if check valve is free.

10. Display indicates to check hydraulic fluid, water strainer, or foam strainer.

The display is programmed to display maintenance reminders at appropriate intervals.

• Perform maintenance action(s) and reset timer per instructions found in para TBD.




MAINTENANCE

11. Water flow reads 000 when flowing water.

Wiring issue. • Check wiring. Unplug the flow meter and check for a good ground, ckt# 1640. Check for 6-9 volt supply to flowmeter, ckt# 2884.

Bad flow meter • Check flow meter. Remove flow meter and check for obstructions or visible damage. Manually spin the paddle wheel and observe the display. Display should indicate flow.

Bad control module. • Check control module. Does the foam module have heartbeat? No heartbeat indicates faulty module.

12. Water in hydraulic oil Defective oil cooler. • Check for carry over in oil cooler. If water is found in the oil, change the oil.

Pressure washing near filler cap on oil reservoir.

• Use caution when pressure washing around oil reservoir.

13. System will not pump foam from foam tank.

• See Table TBD, System Will Not Pump Foam from Foam Tank.

Table 4-2: Specialized Troubleshooting-System Will Not Pump Foam from Foam Tank

Question Reason for Question Test Procedure

A. Is there foam in the foam tank?

The foam system will not operate properly without an adequate supply of concentrate.

Visual inspection.



Fill tank with foam; seeSection 2.No

Yes


MAINTENANCE


B. Is the red light on the control module ON?

A red light indicates that the control head is energized.

Visual inspection.


C. Is the green light on the control module ON?

A green light indicates that the electrical portion of the system is functioning.

Visual inspection.


D. Does the foam pump engage? To isolate the problem from between electrical and mechanical failures.

NOTE: You must be flowing water for the foam pump to operate.

Turn the foam percent up and listen for the foam pump to engage.

Go to Step G.No

Yes

Go to Step K.No

Yes

Go to Step P.No

Yes


MAINTENANCE


E. Tank fill option - look to see if the selector valve is in the TANK FILL mode.

If the tank fill valve is open, all of the foam concentrate will circulate between the foam pump and the foam tank, with little or none being injected.

Remove the tube from the outlet of the tank fill valve. Operate the foam system. If foam concentrate is discharged, the tank fill valve is open.

NOTE: In the TANK FILL mode, the tank to pump valve should be closed automatically. If this does not occur, check for a bad switch at the selector valve.


F. Is the foam injection check valve stuck in the CLOSED position?

Foam concentrate cannot reach the foam injection manifold if the check valve is stuck closed.

Check by visual inspection, or the foam pump may make a squealing noise when the pump goes into the relief mode.


G. Is the wiring OK? The foam system will not operate properly if the wiring is faulty.

Refer to the wiring diagram for circuit information.

Go to Step T.Yes

No

Replace the foam injection check valve.No

End

Repair wiring.No

Yes


MAINTENANCE


H. Is the system voltage OK? Voltage at the control head must be within .2 volt of the battery voltage for the foam system to operate.


1148

• Check the voltage at the control head. Voltage at the control head should be within .2 volt of the battery voltage.

1146

Repair poor connections, loose pins, etc.No

Yes


MAINTENANCE


I. Is the ground circuit OK? The foam system must have an adequate ground (continuity) for the system to operate.

Check ground circuit (ckt# 1640K). Refer to “System Diagrams” on page 4-30 for additional circuit information.

1149


J. Does the control module have a heartbeat?

A flashing red LED (heartbeat) indicates that the control module is communicating with the control head.

Visual inspection.

1147

Repair ground circuit.No

Yes

Replace control module, see service group 7950-P-005.No

Yes

Replace control head.


MAINTENANCE


K. Are there any error messages on the display?

Messages on the display will indicate if there is a low foam level or if the system is being operated beyond its capacity.

Visual inspection.


L. Does the control module have a heartbeat?

A flashing red LED (heartbeat) indicates that the control module is communicating with the control head.

Visual inspection.

1147

Correct problem(s) indicated by the display message.Yes

No

Replace control module, see service group 7950-P-005.No

Yes


MAINTENANCE


M. Is the flow meter operating correctly?

The flow meter provides the foam system with information on how much water is being flowed. No signal from the flow meter will result in the foam system not operating.

If “GPM” appears on the display, the flow meter is OK. If “GPM” does not appear, replace the flow meter.


N. Are the system set-up, LVDT calibration, and defaults set correctly?

The foam system will not operate if the system has not been set-up and calibrated correctly.

See “Set-up & Calibration” on page 4-2:

• Check the set-up;

• Calibrate the LVDT;

• Check all default settings.

Replace flow meter, see service group 7950-P-001.No

Yes

Correct set-up, LVDT calibration & default settings.No

Yes


MAINTENANCE


O. Is the foam tank valve open? The foam pump will not operate unless the system receives a signal that the the foam tank valve is open.

NOTE: It is possible for the valve to be physically open but a failed limit switch indicates to the system that the valve is not open.

• Visually inspect wiring to foam tank valve.

• Check continuity, connectors, etc.

• Check if foam is present at foam pump drain:

a. Open drain on inlet side of foam pump;

b. Open foam tank to pump valve;

c. Check for foam concentrate. If concentrate is present, foam tank valve is open.


P. Does the foam pump engage with the Discharge Foam Pump Drain open?

To check the foam injection check valve. If the foam pump engages with the valve open, it is likely there is contamination in the injection check valve.

Open the Discharge Foam Pump Drain valve. Attempt to operate the system.

Check & repair wiring to valve. Repl valve and/or limit switch.No

End

Clean/replace the injection check valve.Yes

No


MAINTENANCE


Q. Does the foam pump engage in the manual mode?

To isolate the flow meter from the system and eliminate it as a possible cause.

See “Manual Mode” on page 3-9.


R. Is the LVDT working properly? The LVDT informs the system of what the pump is doing. The foam system will not operate properly if no signal is received from the LVDT.

1. Attempt to calibrate the LVDT, refer to “Calibrate Foam Pump (LVDT) Transducer” on page 4-3. If the LVDT will not calibrate, go to Step 2.

2. Remove the cover from the signal condition box.

1153

3. Check for voltage on Pins 5 & 6 (output & ground). A reading of 0-5 volts should be obtained. It is normal for the voltage to fluctuate as the foam pump cycles.

Replace flow meter, see service group 7950-P-001.Yes

No

Replace the LVDT per service group 7950-P-007.No

Yes


MAINTENANCE


S. Is the wiring OK? The foam system will not operate properly if the wiring is faulty.

Refer to “System Diagrams” on page 4-30 for additional circuit information.

Repair wiring.No

Yes


MAINTENANCE


T. Is the system voltage OK? Voltage at the control head must be within .2 volt of the battery voltage for the foam system to operate.


1148


1146

Repair wiring.No

Yes


MAINTENANCE


U. Is the ground circuit OK? The foam system must have an adequate ground circuit (continuity) for the system to operate.

Check ground circuit 1640. Refer to “System Diagrams” on page 4-30 for additional circuit information.

1149

Repair ground circuit.No

Yes

Replace LVDT per service group 7950-P-007.


MAINTENANCE

4-4. Periodic Operation

The foam system should be operated periodically to insure that the foam system is operational, and also to circulate the foam concentrate through the pump. The preferred method is a periodic operation of the system in a normal discharge condition as described in Section 3, “Operation”.

4-5. General Maintenance Procedures

Cleanliness

Dirt, grease, oil, and debris may cover up a serious problem. Use an approved dry cleaning solvent to clean all metal surfaces.


V. Is the electric tank fill valve OK?

If the tank fill valve sticks open, most of the foam concentrate will circulate between the foam pump and the foam tank, with little being injected into the water stream.

Inspect the valve for proper operation. Check the adjustment of the micro switch. Inspect the micro switch for moisture.

1025

Personal hearing can be PERMANENTLY DAMAGED if exposed to constant high noise levels of 85 db or higher. Wear approved hearing protection devices when working in high-noise-level areas. Hearing loss occurs gradually, but becomes permanent over time.

Replace electronic tank fill valve.No

End


MAINTENANCE

Common Hardware

Check bolts, nuts, and screws for obvious looseness, or missing, bent, or broken conditions. Look for rust around bolt heads. Tighten any obvious loose parts.

Weldments

Inspect for rust or gaps where parts are welded together. Broken parts should be repaired or replaced.

Electrical Wiring and Connectors

Look for cracked or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors and make sure wires are in good shape. Repair all bad wiring and connectors.

Lines and Fittings

Look for wear, damage, and leaks. Make sure clamps and fittings are tight. Wet spots can indicate a leak, and a stain around a fitting or connector can also indicate a leak. If a leak originates from a loose fitting or connector, tighten it. Replace any leaking line or fitting.

Hydraulic Tank

The fluid return line, located at the top of the tank, should be cracked open when performing service on the hydraulic system to prevent siphoning of oil that is in the tank.

4-6. Preventive Maintenance Checks and Service

4-6.1 Introduction

These checks and services have been provided to help you keep your equipment in good operating condition and in service.

The preventive maintenance section is intended to formally maintain and document the device on a regular schedule. This schedule is intended as a minimum and is greatly dependent on operating conditions. Heavy use and extreme environmental conditions such as heat, cold, sand, or salt spray will demand increased inspection and maintenance.

This preventive maintenance section is not intended to replace or negate any routine pre-operation safety inspections. The operator must be aware of the condition of the equipment before operating. A pre-operational visual safety inspection should always be performed.

During the warranty period and thereafter, inspections and maintenance schedules must be performed according to the specified Pierce Manufacturing Inc. standards.

Failure to comply with these requirements will be considered grounds or conditions that may void the warranty on individual components, assemblies, or the entire device.

4-6.2 Explanation of Columns

Item No. Numbers in this column are to be used as a source of the item number for the “Item No.” column on the Equipment Inspection and Maintenance Worksheet.

Item to Check/Service This column tells you the item to be checked or serviced. Procedure This column tells you how to perform the required check or service.


MAINTENANCE

4-7. After Every Use Inspection

NOTE: After every use of the system, the following components and systems should be inspected and repaired/replaced as necessary:

4-8. Weekly Inspection

NOTE: After every week of service, perform the following maintenance procedure:

Table 4-3: After Every Use Inspection

Item No. Item to Check/Service Procedure

1 Hydraulic Oil Level

Check the oil level in the hydraulic reservoir.

2 Foam Tank Level Check foam concentrate level in the foam tank and fill as necessary.3 Hydraulic System Check hydraulic tubing/hoses for leaks, loose fittings, damage, etc. 4 Foam System Plumbing Check foam system plumbing for leaks, loose fittings, damage, etc. 5 Manifold Drains Open manifold drain.

Table 4-4: Weekly Inspection


1 Water Strainer

Remove clean-out cap and remove basket. Inspect for foreign debris. If any are found, clean the basket with water and reinstall.

1029

Site Glass 3/4 full is sufficient

Water Strainer


MAINTENANCE

4-9. Quarterly Inspection

NOTE: After every three months of service (quarterly), perform the following maintenance procedure:

4-10. Annual Inspection

NOTE: Annually, perform the Quarterly inspection, then the following maintenance procedure:

4-11. Recommended Hydraulic Oil for Husky 12 Proportioning System

4-11.1 Characteristics

The system is delivered, charged with ISO 68 hydraulic oil. It is recommended that same or similar oil be used to maintain optimum efficiency and component life. If the vehicle has been subjected to extreme cold temperatures for extended periods of time, engaging the water pump will allow the hydraulic oil to warm up before initiating operation of the Husky 12 system.

4-11.2 Recommendations

U.S. Oil Multi-Vis 68R, Mobil DTE16M ISO 68 or equivalent.

Table 4-5: Quarterly Inspection


1 Foam Strainer

Remove clean-out cap and remove basket. Inspect for foreign debris. If any are found, clean the basket with water and reinstall.

1073

Table 4-6: Annual Inspection


1 Hydraulic Oil SampleObtain an oil sample and compare to previous results. If the current sample matches previous test results, the oil does not have to be changed. Replace oil and filter if test results indicate oil degradation.

Foam Strainer


MAINTENANCE

4-11.3 Oil Change Information

We recommend taking an initial sample of hydraulic oil and having it analyzed to serve as a baseline for future oil analysis results. Annually, obtain an oil sample and compare to previous results. If the current sample matches previous test results, the oil does not have to be changed. Replace oil and filter if test results indicate oil degradation.

The hydraulic fluid used for cold weather application may not function properly at higher temperatures, and must be changed to an appropriate recommended type for proper operation of unit.


MAINTENANCE

4-12. System Diagrams

Figure 4-19: Husky 12 Schematic Legend

1256285


MAINTENANCE

Figure 4-20: Husky 12 Hydraulic Schematic

1563671


MAINTENANCE

Figure 4-21: Husky 12 Foam System Schematic

1563917


MAINTENANCE

Figure 4-22: Husky 12 Wiring Harness (except PUC)

64-5033-H001


MAINTENANCE

Figure 4-23: Husky 12 Wiring Harness (PUC only)

64-5116-H001


INDEX

A

Acceptable Foam Concentrate Viscosity Range .............................. 2-2

After Every Use Inspection ........................ 4-27Annual Inspection .................................... 4-28Auto Start ................................................. 4-8

B

Blowing Out After Testing ............................ 4-1

C

Calibrate Class A Foam Mode ...................... 4-4Calibrate Class B Foam Mode ...................... 4-5Calibrate Flowmeter Mode ........................... 4-3Calibrate Foam Pump (LVDT) Transducer ...... 4-3Calibration ................................................ 4-2Characteristics, Hydraulic Oil ..................... 4-28Check Current Software Revision ................ 4-10Class A Foam - Drafting .............................. 3-2Class A Foam - using on-board Foam Tank .... 3-1Class A Tank Fill (Optional) ......................... 3-7Class B Foam - Drafting .............................. 3-3Class B Foam - using on-board Foam Tank .... 3-2Class B Tank Fill (Optional) ......................... 3-8Control Head .......................................... 2-12Control System ....................................... 2-11Controller Module .................................... 2-11Customer Assistance Information ..................... v

D

Description of “DANGER,” “WARNING,” and “CAUTION” .................................... 1-1

Description of Major Components ................. 2-2Discharges ............................................... 2-1Drain Mode .............................................. 4-9Draining Foam Pump After Testing ................ 4-1

E

English/Metric Mode .................................. 4-2Explanation of Columns ............................. 4-26External Pick-Up Connection ....................... 2-8

F

Fill through Foam Tank Fill Dome ................. 3-9Filling Foam Tank(s) .................................. 3-7Flowmeter Operation ................................ 3-10Flush System ........................................... 2-2Flushing After Drafting Class A Foam ............ 3-4Flushing After Drafting Class B Foam ............ 3-5Flushing System ....................................... 3-3Foam Check Valve .................................... 2-9Foam Concentrate Compatibility .................. 2-2Foam Concentrate Pump ............................ 2-6Foam Concentrate Tank ............................. 2-5Foam Proportioner .................................... 2-1Foam Selector Valve ................................. 2-7Foam Supply System ................................. 2-5Foam Supply Valve ................................... 2-6Foam System Operation ............................. 3-1Foam System Schematic ........................... 4-32

G

General Flushing Information ....................... 3-3General Maintenance Procedures ............... 4-25

H

Husky 12 Specifications ............................. 2-1Hydraulic Drive System .............................. 2-2Hydraulic Gear Pump ................................. 2-3Hydraulic Manifold Block ............................ 2-5Hydraulic Oil Cooler ................................... 2-4Hydraulic Oil Filter ..................................... 2-3Hydraulic Oil Reservoir ............................... 2-4Hydraulic Schematic ................................. 4-31Hydraulic Tank ........................................ 4-26

© 2012 Pierce Manufacturing Inc. All Rights Reserved. Husky 12 Foam System / Index-1

INDEX

I

In-line Water Check Valve ......................... 2-10Introduction .............................................. 1-1Introduction, Preventive Maintenance Checks and

Service ....................................... 4-26

L

List of Abbreviations ................................... 1-2

M

Maintenance Introduction ............................ 4-1Maintenance Message ................................ 2-1Manifold Drains ....................................... 2-10Manual Flush Mode ................................... 3-4Manual Mode ............................................ 3-9Master Drain ........................................... 2-10Maximum Foam Solution Flow ..................... 2-1

O

Oil Change Information ............................. 4-29

P

Panel Mounted Strainer .............................. 2-8Periodic Operation ................................... 4-13Pick-Up Hose ........................................... 2-9Preventive Maintenance Checks and Service 4-26Priming System ......................................... 3-5Purpose of Manual ........................................ v

Q

Quarterly Inspection ................................. 4-28

R

Recommendations, Hydraulic Oil ................ 4-28Recommended Hydraulic Oil for Husky 12

Proportioning System .................... 4-28Reset Maintenance Reminders ................... 4-10

S

Schematic Legend ................................... 4-30Scope ......................................................... vSelect Single or Dual Foam Tank System ....... 4-6Set Automatic Flush Time ............................ 4-8Set Class A Concentrate Default Percentage ... 4-5Set Class B Concentrate Default Percentage ... 4-6Set Default Foam Source ............................ 4-7Set-up Mode ............................................. 4-2System Capacity ........................................ 2-1System Diagrams .................................... 4-30System Electrical Load ................................ 2-1

T

Tank Fill Enable/Disable .............................. 4-7Testing After System Maintenance ................ 4-1To the Owner—Operation and Maintenance of This

Apparatus ...................................... 1-1Troubleshooting ....................................... 4-11Troubleshooting, General .......................... 4-11Troubleshooting, Specialized ...................... 4-13

W

Water Flowmeter ..................................... 2-11Water Supply System ................................. 2-9Weekly Inspection .................................... 4-27

Index-2 / Husky 12 Foam System © 2012 Pierce Manufacturing Inc. All Rights Reserved.

Documents

HUSKY 12 GPM - graftonfire.com · © 2012 Pierce Manufacturing Inc. Part No. PM-F-OM130-0212 HUSKY 12 GPM FOAM SYSTEM Operation & Maintenance Manual