Idex HALE SmartCAFS - User Manual

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UV SmartCAFS

Installation and Operation Manual

HALE PRODUCTS, INC.

A Unit of IDEX Corporation

607 NW 27

Ave

Ocala, FL 34475

United States

800-533-3569

800-520-3473

www.haleproducts.com

Halecustomerservice@idexcorp.com









FSG-MNL-00157

REV D, July 2020

Main Page

Revision Record2
- Table of Contents3
T.o.C7
Introduction7
Environmental Protection7
Safety - Relevant Data8
- Maintenance8
- Training8
- Noise9
- Gauges9
- Clutch Engagement9
General Data10
- Compressor10
- Pump10
- Cooling System10
- Foam Proportioning System 3.3 - Class Aandb Foam Compatible10
- Foam Proportioning System 5.0 - Class Aandb Foam Compatible10
- Foam Proportioning System 6.5 - Class Aandb Foam Compatible10
- Foam Proportioning System Dual 6.5 - Class Aandb Foam Compatible10
Lubricants11
- Compressor System11
- Pump Gearbox11
- Clutch Housing11
Maximum Input Rpm11
Model Identification System12
Recommended Foam Agents13
Major Components and Controls14
- General Arrangement14
- Smartcafs Mixing Manifold15
- Foam Unit 3.3, 5.0, 6.5 Foam Pump Component Group17
- Control Panel - Smartcafs18
- Component Panel Cut-Out Dimensions18
System Overview19
- Safety Interlocks Are Provided to Ensure that19
- Compressor19
- Oil Cooler19
- Separator Tank19
- Manifold20
- Foam Unit - Foam Proportioning System20
- Foam Unit 3.3, 5.0, 6.5 System - Remote Mounted21
- Foam Unit Dimensions22
Installation and Initial Set-Up24
- Lifting Points24
- Strap Lift Points24
Drive Line25
- Pump Clearance27
- Panel Strainer28
- Compressor Connections29
- Compressor Oil Service Access30
- Fluid Drain Points31
- Water Drain - Volute Style32
- Water Drain - Q-Series33
System Oil Fill34
- Oil Filling Points34
- Adding Oil34
- Gearbox34
  - Gearbox Oil Filling and Checking34
- Oil Separator Tank35
  - Separator Tank for Compressor Oil36
- Hot-Shift Clutch Housing37
  - Clutch Fluid Filling & Checking37
Schematics38
- Plumbing Connections - Dsd38
- Plumbing Connections - Q-Series40
- Smartcafs200 Interconnection Diagram - Dsd42
- Smartcafs200 Interconnection Diagram - Q-Series43
- Smartcafs200 Interconnection Diagram - All Units44
Foam Tank Low Level Sensor45
Additional Installation Points45
- Foam Tank to Foam Pump45
Vehicle Design Considerations46
Commissioning / Start-Up Procedure47
- Optional Tank Selection for Foam Unit 3.3/5.0/6.548
- Optional Multi-Display Setup/Operation49
  - A ) Setup49
  - B ) Operation50
General Operation51
- Preset Screen (Start Screen)51
- Operating Screen52
Foam/Cafs Operation56
- Engage the Pump56
- Start Foam/Cafs Operation by Selecting a Preset (or Manual)56
- Increase Engine Speed for Desired Water Pressure57
- Selecting a New Preset57
- Modify the Current Operating Parameters57
- Disengaging the Compressor Clutch58
- Overheat Shut down59
- Flushing59
Optional Water Auto-Fill Operation60
- System Layout60
- Components60
- Enabling Auto-Fill61
- Start/Stop Automatic Auto-Fill61
- Manually Open the Auto-Fill Valve62
- Setting the Desired Tank Level for Auto-Fill62
Menus63
- System Menu63
- Setting the System Time63
- User Menu64
- Oem Menu65
Calibrations67
- Water Flow Calibration (Standard)67
- Water Flow Calibration (Direct)70
- Foam Flow Calibration70
Configuration73
- Preset Configuration (Standard)73
- Preset Configuration (Live)74
On-Screen Warnings and Information75
Maintenance Minder76
Routine Maintenance78
- Air Compressor Moisture Drain79
- Oil and Oil Filter80
- Cooling Water Strainer81
- Air Cleaner Element81
Compressor Belt Maintenance82
- Remove Belt Guard82
- Checking Belt Tension83
- Adjusting Belt Tension84
Hot Shift Clutch Maintenance85
- Changing Clutch Oil85
Maintenance Schedule for Smartcafs86
Maintenance Operations Pump - Smartcafs87
- Cafs Mixing Manifold - Greasing Ball Valve87
- Lubricants87
- Vacuum Test Pump Manifold88
- Pressure Test - Performed Without Pump Running88
- Cafs - Setting the Air Balance Control Valves89
  - Symptoms of Improper Adjustment89
  - Functionally Test Smart Cafs Air Pressure /Water Pressure & Adjust Match89
- Cafs - Hot Shift Clutch Engagement91
  - The Hot Shift Clutch Is Engaged When the Cafs Switch Is Activated91
  - Setting the Hot Shift Clutch Engagement91
Recommended Spares Kit for Service92
Hale Pump Illustrated Parts List92
Compressor Illustrated Parts List92
Foam Unit Illustrated Parts List92
Parts List93
- Major Assemblies93
- Smartcafs200 Wiring Harness95
- Thermal Relief Valve97
- Parts List - Suction Manifold98
- Parts List - Discharge Manifold99
- Parts List - Belt Guard & Cafs Mixing Manifold100
- Parts List - Oil Filter & Strainer101
- Parts List - Compressor102
- Parts List - Separator, Oil Reservoir104
Quick Reference Guide/Troubleshooting107
- Air Injection/Control107
- Compressor Operation110
- Cafs Operation114
Limited Warranty116

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Idex HALE SmartCAFS Specifications

General

Brand	Idex
Model	HALE SmartCAFS
Category	Water Pump
Language	English

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