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HALE SmartCAFS
Idex HALE SmartCAFS User Manual
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©HALE
PRODUCT
S,
INC.
Our
policy
is
one
of
c
ontinuous
develo
pment.
We
therefore
reserve the right
to amend specifi
cations without
notice or ob
ligation.
MAJOR COMPO
NENTS AN
D CONTROLS
GENERAL ARRANGEMENT
Figure 2: Q-SERIES version shown. Drawing numbers are shown in brackets [FSG-
PL
-
XXXXX].
Master Drain System
(Optional)
In Line Driven Gearbox
w/Integrated Cooler and
Clutch
Compressed Air / Oil
Separator Tank
[FSG-
PL
-01307]
Compressor Oil Filter
Rotary Twin Screw
Compressor
[
FSG-
PL
-01306]
Tank to Pump
Valve
(Optional)
Plate Style Oil
Cooler
(Heat Exchanger)
Suction Manifold
w/MIV
Suction Manifold
w/MIV & Fill Thief
CAFS Manifold
Discharge Manifold
Anodes
(2) Suction
(2) Disc
h
a
rge
13
15
Table of Contents
Revision Record
2
Table of Contents
3
T.o.C
7
Introduction
7
Environmental Protection
7
Safety - Relevant Data
8
Maintenance
8
Training
8
Noise
9
Gauges
9
Clutch Engagement
9
General Data
10
Compressor
10
Pump
10
Cooling System
10
Foam Proportioning System 3.3 - Class Aandb Foam Compatible
10
Foam Proportioning System 5.0 - Class Aandb Foam Compatible
10
Foam Proportioning System 6.5 - Class Aandb Foam Compatible
10
Foam Proportioning System Dual 6.5 - Class Aandb Foam Compatible
10
Lubricants
11
Compressor System
11
Pump Gearbox
11
Clutch Housing
11
Maximum Input Rpm
11
Model Identification System
12
Recommended Foam Agents
13
Major Components and Controls
14
General Arrangement
14
Smartcafs Mixing Manifold
15
A ) Volute Style Pump
15
B ) High Pressure
16
C ) Standard Pressure
16
Foam Unit 3.3, 5.0, 6.5 Foam Pump Component Group
17
Control Panel - Smartcafs
18
Component Panel Cut-Out Dimensions
18
System Overview
19
Safety Interlocks Are Provided to Ensure that
19
Compressor
19
Oil Cooler
19
Separator Tank
19
Manifold
20
Foam Unit - Foam Proportioning System
20
Foam Unit 3.3, 5.0, 6.5 System - Remote Mounted
21
Foam Unit Dimensions
22
Installation and Initial Set-Up
24
Lifting Points
24
Strap Lift Points
24
Drive Line
25
Pump Clearance
27
Panel Strainer
28
Compressor Connections
29
Compressor Oil Service Access
30
Fluid Drain Points
31
Water Drain - Volute Style
32
Water Drain - Q-Series
33
System Oil Fill
34
Oil Filling Points
34
Adding Oil
34
Gearbox
34
Gearbox Oil Filling and Checking
34
Oil Separator Tank
35
Separator Tank for Compressor Oil
36
Hot-Shift Clutch Housing
37
Clutch Fluid Filling & Checking
37
Schematics
38
Plumbing Connections - Dsd
38
Plumbing Connections - Q-Series
40
Smartcafs200 Interconnection Diagram - Dsd
42
Smartcafs200 Interconnection Diagram - Q-Series
43
Smartcafs200 Interconnection Diagram - All Units
44
Foam Tank Low Level Sensor
45
Additional Installation Points
45
Foam Tank to Foam Pump
45
Vehicle Design Considerations
46
Commissioning / Start-Up Procedure
47
Optional Tank Selection for Foam Unit 3.3/5.0/6.5
48
Optional Multi-Display Setup/Operation
49
A ) Setup
49
B ) Operation
50
General Operation
51
Preset Screen (Start Screen)
51
C ) Preset Buttons
51
D ) Water Flow Display
52
E ) Home Button
52
F ) Menu Button
52
Operating Screen
52
G ) Water Flow Display
52
H ) Foam Flow Capacity
52
I ) Foam Percentage Indicator
53
J ) Foam Power Button
53
K ) Foam Increase and Decrease Buttons
53
(L) Air/Water Pressure Duplex Gauge
53
M ) Home Button
53
N ) Current Preset
53
O ) Air Display
54
(P) CAFS Air/Water Flow Ratio
54
Q ) Cafs Arc Valve Position
54
R ) Cafs Power Button
54
S ) Cafs Wet and Dry Buttons
54
(T) Tank-To-Pump Valve Button
54
(U) Auto-Fill Manual Button
55
(V) Auto-Fill ON/OFF Button
55
W ) Menu Button
55
X ) Additional Information Display
55
Foam/Cafs Operation
56
Engage the Pump
56
Start Foam/Cafs Operation by Selecting a Preset (or Manual)
56
Increase Engine Speed for Desired Water Pressure
57
Selecting a New Preset
57
Modify the Current Operating Parameters
57
Disengaging the Compressor Clutch
58
Overheat Shut down
59
Flushing
59
Optional Water Auto-Fill Operation
60
System Layout
60
Components
60
Enabling Auto-Fill
61
Start/Stop Automatic Auto-Fill
61
Manually Open the Auto-Fill Valve
62
Setting the Desired Tank Level for Auto-Fill
62
Menus
63
System Menu
63
Setting the System Time
63
User Menu
64
Y ) Up/Down Arrow Buttons
64
"+" and "-" Buttons
65
Aa ) Exit Button
65
Oem Menu
65
Bb ) Save Button
65
CC ) Up/Down Arrow Buttons
66
DD ) "+" and "-" Buttons
66
Ee ) Exit Button
66
Ff ) Save Button
66
Calibrations
67
Water Flow Calibration (Standard)
67
Water Flow Calibration (Direct)
70
Foam Flow Calibration
70
Configuration
73
Preset Configuration (Standard)
73
Preset Configuration (Live)
74
On-Screen Warnings and Information
75
Maintenance Minder
76
Routine Maintenance
78
Air Compressor Moisture Drain
79
Oil and Oil Filter
80
Cooling Water Strainer
81
Air Cleaner Element
81
Compressor Belt Maintenance
82
Remove Belt Guard
82
Checking Belt Tension
83
Adjusting Belt Tension
84
Hot Shift Clutch Maintenance
85
Changing Clutch Oil
85
Maintenance Schedule for Smartcafs
86
Maintenance Operations Pump - Smartcafs
87
Cafs Mixing Manifold - Greasing Ball Valve
87
Lubricants
87
Vacuum Test Pump Manifold
88
Pressure Test - Performed Without Pump Running
88
Cafs - Setting the Air Balance Control Valves
89
Symptoms of Improper Adjustment
89
Functionally Test Smart Cafs Air Pressure /Water Pressure & Adjust Match
89
Cafs - Hot Shift Clutch Engagement
91
The Hot Shift Clutch Is Engaged When the Cafs Switch Is Activated
91
Setting the Hot Shift Clutch Engagement
91
Recommended Spares Kit for Service
92
Hale Pump Illustrated Parts List
92
Compressor Illustrated Parts List
92
Foam Unit Illustrated Parts List
92
Parts List
93
Major Assemblies
93
Smartcafs200 Wiring Harness
95
Thermal Relief Valve
97
Parts List - Suction Manifold
98
Parts List - Discharge Manifold
99
Parts List - Belt Guard & Cafs Mixing Manifold
100
Parts List - Oil Filter & Strainer
101
Parts List - Compressor
102
Parts List - Separator, Oil Reservoir
104
Quick Reference Guide/Troubleshooting
107
Air Injection/Control
107
Compressor Operation
110
Cafs Operation
114
Limited Warranty
116
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Idex HALE SmartCAFS Specifications
General
Brand
Idex
Model
HALE SmartCAFS
Category
Water Pump
Language
English
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