Operation & Maintenance Manuals

Chernguard Job No. 69327

PROVEER SURAMERICANA LTDA Purchase arder No. 1-0434

Chemguard

204 S. Sixth Ave.

Mansfield, TX 76063 U.S.A

PHONE: 817-473-9964

FAX: 817-473-0606

WWW.CHEMGUARD.COM

List of pump skid equipment supplied with:

Chemguard Job No. 69327
Proveer Suramericana LTDA Purchase Order No. 1-0434

Ouantity Eguipment
2 ea. Balanced Pressure Proportioning Pump Skids to inelude the following:
1 ea. Foam concentrate pump, electric motor driven, rated 45 gpm at
200 psi
1 ea. Foam concentrate pump, diesel engine driven, rated 45 gpm at
200 psi
1 ea. Foam pump controller, electric drive
1 ea. Foam pump controller, diesel drive
1 ea. Pressure balancing valve
1 ea. Ratio flow controller, 4" Proportioner, 3%FP (ANGUS FP-70)
2 ea. Pressure relief val ves
1 lot Control val ves, interconnecting piping, pressure gauges, etc. to
make complete functioning skid.
2 ea. Foam Concentrate Storage Tanks, 1050 Gallon Capacity
2 ea. Flexible Connections, Model CVMC2.0, Zn Plated, 2", Flanged
2 ea. Flexible Connections, Model CVMC2.5, Zn Plated, 2.5", Flanged
 TABLE OF CONTENTS
SECTION 1................... Manual - Balanced Pressure Proportioning Pump Skid

SECTION 2 ................... Manual- Foam Concentrate Pump, CGP80 Series

SECTION 3 ................... Manual- Foam Concentrate Pump Controller, Electric Drive

SECTION 4 ............. ..... .Manual - Foam Concentrate Pump Controller, Diesel Drive

SECTION
,.:-'
5 ................... Manual- Foam Concentrate Pump Pressure ReliefValve

SECTION 6 ................... Manual - Electric Motor

SECTION 7.. ................. Manual - Electric Motor Coupling

SECTION 8.. .. ...............Manual- Diesel Engine

SECTION 9 ................... Manual - Diesel Engine Drive Shaft

SECTION 10................. Manual - Diesel Engine Fuel Tank

SECTION 11 ... ..............Manual- Foam Concentrate Storage Tank

SECTION 12.................Manual- Foam Concentrate Storage Tank Low Level Switch

SECTION 13 ................. Certificate - Factory Authorized Testing (Proportiorung)

SECTION 14................. Test Reports

SECTION 15................. Drawings - Balanced Pressure Proportioning Pump Skid

 OIPERATING & MAINTENANCE MANUAL

WITH FILlING INSTRUCTIONS

CflEMGUARD I , I I I , I I
! N e o R POR A T E o

BALANCED PRESSURE
PROPORTIONING SYSTEMS

rHEMGUARD,~ 204 S. 6th Aven"e • MansOeld,Texas, USA 76063 • (817) 473-9964 • FAX, (817) 473-0606
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TABLE OF CONTENTS

Text Table 01 Contents........................................................................................................................................ Page

CHAPTER 1 - INTRODUCTION

Chemguard Ine. Emergeney 8erviee........................................................................................................... 1-1

Chemguard, Ine. Address, Telephone and E-Mail Numbers...................................................................... 1-1
Warning-Failure to Read Manual................................................................................................................. 1-2
1-1 8alety Inlormation....................................................................................................................................... 1-2
1-2 General Deseription.... 1-3
1-3 General Noles............................................................................................................................................. 1-4

CHAPTER 2 ·INSTALLATION

Caution: Installation..................................................................................................................................... 2-1

Warning: Inspeetion and Testing Alter Installation...................................................................................... 2-1
Caution: Customer Modilieation 01 Equipment......... 2-1
Note: Read AII Operating Instruetions......................................................................................................... 2-1
Note: Componets lor a Balaneed Pressure Proportioning 8ystem............................................................. 2-1
2-1 Reeommended Materials 01 Construetion................ 2-2
2-2 Installation and Start-Up: Skid Mounted Proportioning System.................................................................. 2-3
A. Site Seleelion..................................................................... 2-3
B. Off Loading............................................................................................................................................. 2-3
C. Installation.............................................................................................................................................. 2-3
2-3 Installation and Start-Up: System 8upplied as Loose Components :.......................................... 2-6
2-4 Tesling Alter Installation.............................................................................................................................. 2-8

CHAPTER 3· OPERATING PROCEDURES

3-1 Operation 01 Manual System.................................... 3-1

3-2 Manual System Over-ride (Manual Regulation}........................................................................................... 3-1
3-3 Shutdown... 3-2
3-4 Automatie Operation 01 System................................ 3-2
3-5 Minimum Inlet Pressure Requirements....................................................................................................... 3-3
Figure 3-2 Chemguard Ratio Controller Minimum Inlet Pressure vs. Solution FlowChart......................... 3-3

CHEMGUARDIIl":. 204 S. 6th Avenue • Mansfield. Texas. USA 76D63 • (Si?) 473·9964 • FAX: (817) 473-0606
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TABLE OF CONTENTS (CONTINUED)

Text CHAPTER 4 - INSPECTION AND MAINTENANCE Page

4-1 Inspection and Maintenance....................................................................................................................... 4-1

4-2 Testing Afler System Maintenanee............................................................................................................. 4-1
4-3 AnnualTesting............................................................................................................................................ 4-2
Table 4-1 Fleeommended Inspeetion & Maintenanee Sehedule................................................................. 4-2
4-4 Total System............................................................................................................................................... 4-3
4-5 Strainers.................................................................... 4-3
4-6 Foam Coneentrate Pump................................... 4-3
4-7 Eieetieally Aetuated Valves......................................................................................................................... 4-4
4-8 Water Powered Ball Valves......................................................................................................................... 4-4
4-9 PneumatieallyAetuated Valves................................................................................................................... 4-4
4-10 Pressure Vaeuum Vent............................................................................................................................... 4-4
4-11 Foam Coneentrate Storage Tank................................................................................................................ 4-5
4-12 Foam Concentrate...................................................................................................................................... 4-5
4-13 Control System............................................................................................................................................ 4-5
4-14 Flushing - Foam Coneentrate Piping........................................................................................................... 4-5

CHAPTER 5 - TROUBLESHOOTING

5-1 Troubleshooting Introduetion....................................................................................................................... 5-1

Table 5-1 Troubleshooting.......................................................................................................................... 5-1
5-2 No Proportioning....................................................... 5-1
5-3 Low Pereent 01 Proportioning...................................................................................................................... 5-3
5-4 High Pereent 01 Proportioning..................................................................................................................... 5-5
5-5 No Flow at Diseharge Deviee(s).................................................................................................................. 5-5
5-6 Low Flow al Diseharge Deviee(s)................................................................................................................ 5-6
5-7 Foam Coneentrate Pump not Running........................................................................................................ 5-6
5-8 No Operation ,.................................................................................................................... 5-6

CHAPTER 6 - SCHEMATIC DRAWINGS

6-1 Figure 2-1 Balaneed Pressure Skid Pak with 21/2" - 8" (3% Proportioning).............................................. 6-1
Figure 2-2 Balaneed Pressure Skid Pak with 21/2" - 8" Ratio Controller (6% Proportioning).................... 6-2
Figure 3-1 Operating Sehematie Drawing................................................................................................... 6-3

CHEMGUARO.Nt: 204 S. 6th AvenuE • Mansfield, Texas, USA 76063 • (817) 473-9964 • FAX: (817) 473-0806
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CI-IAPTER 1 - INTRODUCTION

CHEMGUARD, INC.

"GuardianAlert"TM Fire Emergeney Serviee

Chemguard,lne.'s "GuardianAlert"TM Emergeney Serviee is a system designed to respond to

emergeney situations.

Fire, hazardous material spill, or any other emergeney serviee Chemguard, Ine. can provide is
available 24 hours a day, 365 days a year. A "GuardianAlert"TM Emergeney eall will be handled by
a qualified Chemguard, Ine. professional who will respond to your needs and satisfy your
requirements for emergeney foam, equipment or serviee, and work with you until the emergeney
is under control.

Call the "GuardianAlert"TM telephone number anytime, anywhere in the world for Chemguard, Ine.
emergeney serviee or produets.

"GuardianAlert"TM

817-473-9964

Mansfield, Texas USA

E-mail: info@ehemguard.eom

Chemguard, Ine. stands ready to assist in the event of any emergency!

CHEMGUARD. CHEMGUARD, INC.

204 S. Sixth Ave.
I N e o R POR A T E D Mansfield, TX 76063 USA

CHEMGUARD,NC 204 S. 6th AvenUE • Mansfield, Texas. USA 76063 • (BH} 473·9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 1-2

o WARNING:This manual has been prepared as an aid and guide for personnel
involved in the installation, operation and maintenanee of a Chemguard,
Ine. Balanee Pressure Proportioning System. AII instruetions must be
read and understood thoroughly before attempting any installation,
operation or maintenanee to this system. Failure to follow any
instruetions eould result in personal injury ancl!or damage to this
equipment.

1-1 SAFETV INFORMATION

Various Danger, Warning, Caution and Note signal words appear in the Operating and
Maintenance Manual text which must be observed for safe personnel and equipment operation.
Signal word selection is base upon hazard classification.

The International Alert Symbol· O. is used with the signal word to gain and direct operating
personnel's attention to the signal word.

The following explains each signal word. Personnel operating and maintaining equipment must
familiarize themselves with each particular signal word's intent.

o DANGER signal words indicate an extremely hazardous situation which, if not avoided,
will result in death or serious injury to the operator.

O WARNING signal words indicate a potentially hazardous situation which, if not avoided,
could result in serious injury to the operator.

O CAUT~ON signal words indicate the following:

1. A potentially hazardous situation which, if not avoided, may result in minor or
moderate injury
2. A potentially hazardous situation which, if not avoided, may damage or destroy
equipment or cause a loss of operating effectiveness
3. Alert operating personnel to unsafe practices

NOTE signal words indicate statements which must be observed for essential and
effective operating procedures, conditions, and statement

It is the responsibility of all personnel involved in the operating and maintenance of this equipment
to fully understand the DANGER, WANING, CAUTION, and NOTE procedures by which hazards
are to be reduced or eliminated. Personnel must become thoroughly familiar with all aspects of
safety and equipment prior to operation or maintenance of the equipment.

Operating and Maintenance instructions and layouts shall be posted at control equipment with a
second copyon file. AII persons who may be expected to inspect, test, maintain or operate foam-
generating apparatus shall be thoroughly trained in the functions they are expected to perform.
(NFPA 11, para 7-3, Operating Instructions and Training)

CHEMGUARD,M:. 2D4 S. 6th Avenue D Mansfield. Texas, USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
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1-2 GENERAL DESCRIPTION

The Chemguard Balanced Pressure Proportioning System is designed to inject foam concéntrate
into the Water supply at the correct percentage. This system will automatically and accurately
proportion over a wide range of flows and pressures without manual adjustments.

The principleof operation is based on the use of a modified venturi proportioner commonly called
a ratio controller. As water flows through a jet at the inlet of the ratio controller, it creates a
reduced pressure area between the jet and a downstream section called a throat or receiver. This
reduction in pressure causes foam concentrate to flow through a foam concentrate metering
orifice and into the reduced pressure area.

As the water ñow through the ratio controller jet increases, so does the level of pressure
reduction, thereby affecting a corresponding pressure drop across the foam concentrate metering
orifice. This corresponding pressure drop results in a foam coneentrate flow whieh is
proportionate to the water flow through the ratio eontroller. As both the water and foam
concentrate ñow into a eommon redueed identieal water and foam redueed pressure area, it is
necessary only to maintain identieal water and foam eoneentrate pressures at the respective inlets
of the ratio eontroller.

Pressure sensing lines lead from the ratio eontroller foam eoneentrate sensing eonneetion and
water supplyline. upstream of the ratio eontroller, to the foam eoneentrate and water sensing
inlets on the diaphragm valve. The diaphragm valve automatieally adjusts the foam eoneentrate
pressure to eorrespond to the water pressure. A duplex gauge indieates balaneing of both the
foam eoneentrate and water pressures at the ratio eontroller.

For manual regulation, the diaphragm valve ls not required. The pressure of the foam
eoneentrate is adjusted to eorrespond to the water pressure by means of a manually operated
valve in the foam eoneentrate bypass piping.

Chemguard Balaneed Pressure Proportioning Systems are suitable for use with all foam
eoneentrates and either fresh or salt water.

• A Chemguard Foam Skid Mounted Balaneed Pressure Proportioning

System eonsists of the following major components:

• Ratio Controller - proportions quantity of foam eoneentrate required into the water supply.
Model size varies aeeording to foam system requirements. System may be supplied with
multiple ratio eontrollers.

• Foam Pump - with relief valve, driver and starter/eontroller. GPM and PSI pump rating vary
aeeording to foam system requirements. May be supplied with primary/seeondary foam
pumps (Eleetrie and/or diesel)

• Diaphragm Valve - balaneing valve. Maintains equal foam eoneentrate and water supply
pressures at ratio eontroller.

• Dúplex Pressure Gauge - indieates foam eoneentrate and water pressures.

CHEMGUARD,ron: 204 S. 6th Avenue o Mansfield. Texas, USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 1-4

• Compound Gauge - indicates pressure/vacuum at foam pump suction.

• Foam concentrate PipingNalves - brass/bronze is standard.

• Complete Automation of System is optional.

Specification:

Skid mounted balanced pressure proportioning system shall be a complete self-contained

unit designed to proportion foam concentrate with water at the required percentage of
concsntratlon over a wide flow range. AH foam concentrate proportioning components and
pipingshall be securely mounted on a welded structural steel channel base frame,
complete with foundation anchor bolt holes and Iifting lugs. Skid shall include all necessary
piping, valves and fittings to comprise a complete foam proportioning unit. AH field
connections shall be 150 lb. R.F. flange flush with the edge of the skid base.

AH valving shall be arranged to permit routine checking of the foam concentrate pump and
driver and periodic circulation of foam concentrate in the skid piping.

The unit shaH be completely assembled and tested where possible, at the factory.

1·3 GENERAL NOTES

1. AH correspondence relating to this system should refer to the sales order number, file number,
user name and location.

2. Before instaHation is begun, the final plans and design data should be presented to the
authorities having jurisdiction.

3. Chemguard recommends that those individuals charged with designing, installing, operating,
testing and maintaining a foam fire protection system, or the replacement of equipment and/or
components of an existing system refer to the appropriate authority having jurisdiction for
compliance with applicable standard(s), code(s) and regulation(s) for that particular type of
system and its components.

4. Chemguard concentrates must be maintained and stored within certain specified

temperatures, containers and conditions. Failure to foHow Chemguard's guidelines regarding
these concentrates can compromise their eftectiveness. Refer to Chemguard's Service
Department for specific recommendations.

5. The foamsystem provided is based on specific design requirements, that ls, products(s) being
protectedand area(s) of coverage. The design requirements may or may not have been
provided to Chemguard. Any changes to the area(s) of coverage or additions of other
products could exceed the design parameters of the system. Contact Chemguard's
Engineering Dept. for questions regarding changes to designo

6. Before operatlnq the system, the foam concentrate pump should be serviced in accordance
with the manufacturer's instaHation and maintenance sheets and the recommended start-up
procedures outlined in this manual.

rHEMGUARD~'.JC 204 S. 6th Avenue 11 Mansfíeld, Te:xas, USA 76063 • (B17) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTlONING SYSTEM 1-5

7. In accordance with the requirements of NFPA 11, Chemguard recommends that the system be
inspected and tested by qualified personal. Testing shall meet the approval of the authority
having jurisdiction, and as a minimum, shall be as outlined in NFPA 11 to insure that the
system has been properly installed and will function as intended. The services of a qualified
field engineer are available to perform this testing and inspection. Please contact
Chemguard's Service Department for additional details. If initial start-up tests are carried out
by persons not employed by Chemguard, please forward copies of the inspection test report
to the Chemguard Service Department.

8. AII electric:al installations and equipment must conform to the provisions of the National
Electrical Code and also all local codeso

o WARNING: Judgement must be used in applying foams to hot oils, burning

asphalts or burning liquids which are aboye the boiling point of water.
Intermittent foam operation should be used to prevent violent frothing and
"slop-over" of the tank contents.

o WARNING: Foam is a conductor and shall not be used on energized electrical

equipment fires.

o WARNING: Foams are not suitable extinguishing agents for fires involving
gases, liquefied gases with boiling points below ambient temperatures such
as butane, butadiene, propane, etc. or cryogenic Iiquids.

CHEMGUAB.D,
INCORPORATED

CHEMf;UARD""c.. 204 S. 6th Avenue • Mansfield. Texas, USA 76063 • (817) 473·9964 • FAX: (817) 473-0608
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CHAPTER 2 -INSTALLATION

O· CAUTION: Install the Balaneed Pressure Proportioning System in aeeordanee

with instruetions in this manual. Variations may affeet performance or cause
system failure.

o WARNING: Chemguard, Ine. reeommends the system be inspeeted and tested

after installation and prior to final aeeeptanee. The eompleted system shall be
tested by qualified personnel to meet the approval of the authority having
jurisdietion. These tests shall be adequate to determine that the system has
been properly installed and will funetion as intended (NFPA 11, para. 6-3,
Aeeeptanee Tests). Before aeeeptanee, all operating deviees and equipment
shall be tested for proper funetion (NFPA 11, para. 6-3.2, Operating Tests).
Where eonditions permit, a flow test shall be eonducted to ensure that the
hazard is fully proteeted in eonformanee with the design speeifieation .
(NFPA 11, para. 6-3.3, Diseharge Tests).

The serviees of a qualified field engineer are available to perform this testing
and inspeetion. If initial start-up inspeetion and test are earried out by
persons not employed by ehemguard lnc, please fouward copies of the
inspeetion test reports to Chemguard, Ine.'s Serviee Department.

o CAUT~ON: Customer modifieations or alteration of thls equipment, or the use

of replacernent parts other than those speeified by Chemguard, Ine., may
affeet the performance of this equipment and may void the warranty.

NOTE: READ ALL OPERATING INSTRUCTIONS BEFORE USING EQUIPMENT.

It is the responsibility and duty of all personnel involved in the installation, operation, inspeetion
and maintenanee, and refilling of this system to read and understand this entire manual befo re
using the equipment.

NOTE: COMPONENTS FOR A BALANCED PRESSURE PROPORTIONING SYSTEM.

Produets manufaetured by Chemguard are warranted free of defeets in materials and work-
manship for twelve months from the date of purehase. Chemguard will pass on to the owner, as
far as it is able to do, the benefit of the manufaeturer's warranty for those parts and eomponents
not manufaetured by Chemguard, Ine.

Chemguard,lne. may supply eomponents sueh as a ratio eontroller, diaphragm valve, gauges,
controls, etc. for use in new or refurbished balaneed pressure systems. Chemguard, Ine. makes
no warranty,either expressed or implied and assumes no responsibility on the engineering and
design of sueh systems.

CHEMt;UARD,NC 204 S. 6th Avenue • Mansfield. Texas, USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 2-2

2-1 RECOMMENDED MATERIALS OF CONSTRUCTION

NOTE: The following reeommendations are for materials whieh will be in eontaet with the foam
eoneentrates.

o CAUTION: Galvanized steel storage tanks or piping must neverbe used to

contaln any foam concentrates.

1. With Synthetic Based Polar SolventlAFFF and Conventional AFFF Foam Concentrates

a. Piping:

• Brass or Branze (Note: AII foam eoneentrate lines on standard Chemguard skid paks are
brass)
• Stainless Steel 304L or 316 grades
• High density polyethylene
• PVC
• Fiberglass with isophthalie based polyester and an internallayer (50-100 mils ,minimum)
of vinyl ester resin in eontaet with foam eoneentrate

b. veives:

• Brass or bronze. Cast brass valves filled with stainless steel (304L or 316 grades) or brass"
trim are aeeeptable. Teflon seats and paeking are preferable for foam eoneentrate serviee.
EPT (EPDM), Buna-N or Viton are also aeeeptable seal materíals for use with Chemguard
foam eoneentrates.
• Stainless steel304L or 316 grades

e. Storage Tanks:

• High Density Cross Linked Polyethylene

• Fiberglass with isophthalie based polyester and an internallayer (50 -100 mils minimum) of
vinyl ester resin in eontaet with foam eoneentrate
• Stainless steel 304L or 316 grades

2. With Protein-Based Foam Concentrates

a. Piping:

• Same materials as Synthetie Based Polar Solvent/AFFF and Conventional AFFF Foam
Concentrate with the exception of stainless steel
• Black steel pipe and malleable iron fillings

CHEMGUARDwr 204 S. 6th AvenuE • Mansfleld, Texas. USA 76063 • (817) 473-9964 • FAX: (817) 473·0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 2-3

b. Va/ves:

• Brass or bronze. Cast brass valves fitted with stainless steel (3D4L or 316 grades) or brass
trim are acceptable. Teflon seats and packing are preferable for foam concentrate service.
EPT (EPDM), Buna-N or Viton are also acceptable seal materials for use with Chemguard
foam concentrates.

c. Storage Tanks:

• Steel
• Same materials as Synthetic Based Polar SolventiAFFF and Standard AFFF Foam
Concentrate with the exeeption of stainless steel

2-2 INSTALLATlON AND START-UP: SKID MOUNTED PROPORTIONING SYSTEM

Refer to Fig. :2-1 for a 3% proportioning system or Fig. 2-2 for a 6% proportioning system.

A. Site Selection

1. The proportioning skid should be located on a flat and level surface large enough to
support the entire skid frame.

2. The preferred base is concrete.

B. OffLoading

1. Do notmove the skid using piping or installed equipment as a Iifting device. Use a crane
or other suitable Iifting apparatus to move the skid. Uft with a lift truck from the underside
of the skid frame.

C. Installation

o WARNING: Automated Foam Fire Protection System -In an Automated Foam

Fire Protection System where manually operated valve(s) are used in the foam
solution line from the proportioner to the discharge device(s), Chemguard
l;trongly recommends that all manual valve(s) be ehained or locked in the
open position or equipped with tamper alarm switch (es) which are monitored
by a supervisory alarm panel. :

Chemguard, Ine. is concerned about the possibility that any manually

operated valve(s) in the foam solution line to the hazard(s) could inadvertently
be left in the elosed position during a fire condition. This situation would
prevent the foam solution from reaching the hazard(s) in the event of an
autornatlc trip sequenee.

rHEMGUARD,~ 204 S. 6th Aven"e • Manstield. Texas. USA 76063 • (B17) 473-9964 • FAX: (B17) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTlONING SYSTEM 2·4

1. The skid should be suitably ancho red to eliminate vibration and movement. Level and
shim as neeessary. Chemguard reeommends a elear distanee of 2 ft. (0.6096m) on the
pump end and 3 ft. (0.9144m) on the drive end be allowed by the installer to faeilitate
serviee/removal of the pump and motor.
NOTE:: AII field eonneetions, with the exeeption of the water/foam solution eonneetion at
the ratio eontroller, shall be flush with the edge of the base plate.

2. Remalle and diseard any shipping support braeket befare installing the skid unit into the
pipingsystem.

3. If not provided by Chemguard and to faeilitate future serviee/removal of the ratio eontroller,
the installer should provide a spool pieee upstream of the ratio eontroller. See ehart whieh
follows far minimum spool pieee lengths.

Ratio Controller Minimum Spool Length

2.5" 6" (150mm)
3" 8" (203mm)
4" 1O" (254mm)
6" 12" (305mm)
8" 14" (356mm)

4. A minimum of five (5) pipe diameters of straight unobstrueted pipe is required upstream
and downstream of eaeh ratio eontroller.

5. AII intereonneeting piping must be self-supported. Plastie foam eoneentrate storage tanks
must have flexible eonneetion fittings installed between the tank and proportioning
equipment to eliminate stress imposed by the piping and to eliminate vibration.

6. Chemguard hydrostaetieally tests and where possible, flow tests all skid units befare they
leave the faetory. However, due to vibration and handling experieneed during transit, the
tightness of joints on tlle skid eannot be guaranteed. Therefore, Chemguard reeommends
that the installer hydrostatieally test the skid piping in aeeordanee with proeedures outiined
in the latest edition NFPA 11, befare introdueing foam eoneentrate into the system.

7. Flush the foam eoneentrate piping befare introducing foam eoneentrate into the foam
system. Refer to Chapter 4, Seet. 4-14 for foam eoneentrate piping flushing proeedures.

8. Flush tlle water lines and all foam solution lines. The foam solution lines shall be flíJshed at
or aboye design flow rates. The flushing shall be done prior to installing any foam makers,
sprinklers or nozzles.

CHEMC:;UARD,NC 204 S. 6th Avenue • Mansfield, Texas, USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
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NOTE: In order to remove foreign materials that may have entered during installation, water
supply mains, both under- ground and aboveground, shall be flushed thoroughly at the maximum
practical rateof flow before connection is made to system piping. The minimum rate of flow for
flushing shallnot be less than the water demand rate of the system, as determined by the system
designo The flow shall be continued for a sufficient time to ensure thorough cleaning. Disposal of
flushing water must be suitably arranged. AII foam system piping shall be flushed after
installation, using its normal water supply with foam forming materials shut off, unless the hazard
cannot be subjected to water f1ow. Where flushing cannot be accomplished, pipe interiors shall
be carefully visually examined for cleanliness during installation. (NFPA 11, para. 6-2, Flushing
After Installation)

9. After flushing, remove all strainer screens and clean. Reinstall screens after cleaning.

10. Check that the system is properly installed according to design with all necessary valves,
corree! pipe size, discharge device locations and is installed in compliance with local
codeso

11. Service foam concentrate pump before installation into the system. Service pump, reducer
and motor in accordance with the manufacturer's recommendations. Be sure that the
reducer is filled with oil and the pump and motor are lubricated. The pump body is coated
with a petroleum based rust preventative for protection during shipment. The pump drain
plug must be removed, anyexcess Iiquid drained and the plug reinstalled. The pump must
then be flushed with mineral spirits for approximately five (5) minutes and then drained.
Finally, it must be flushed with water. Always rotate the pump by hand to be sure it turns
freely before start-up, Never start-up the pump when it is dry. .

O WARNING: For Petroleum Based Rust Preventative

• Refer to Material Safety Data Sheet

• Avoid contact with stronq oxidizing agents
• May cause skin and eye irritation
• Inhalation of mist may cause irritation of nasal and respiratory passages
• Swallowing may cause mouth and gastrointestinal irritation

12. Check alignment of all pump and motor shaft couplings to manufacturer's
recommendations.

13. Check the foam concentrate pump motor and controller to insure it is wired properly.

14. Check the motor rotation to insure it is running in the correct direction to allow proper foam
concentrate pump rotation. "Bump" run the motor (and pump) by alternately actuating the
"ON" and "OFF" buttons until the direction of rotation is determined. Correct if necessary.

15. If the pump is driven by a gasoline or diesel engine, refer to the manufacturer's start-up and
installation instructions prior to using.

rHEMGUARO,~ 204 S. 6th Aven"• • Mansfi.ld. Texas, USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 2-6

16. If the foam concentrate pump is driven by a gasoline or diesel engine, anti-vibration
connections must be installed in the foam concentrate line on both the inlet and outlet sides
of the pump. Also, anti-vibration fittings must be installed on the foam concentrate pump
base if the base is skid mounted.

17. If the system has automatic valves, check these valves to insure that they open and elose
properly

18. Place all valves in their standby position. Refer to Normal standby Valve Position Chart
on Operating Schematic Dwg. Fig.3-1.

19. It may be desirable to install shutoff valves between the foam concentrate storage tank and
the flexible connections in addition to Valves A & B, which are on the proportioning skid.
These valves will be useful if the foam concentrate piping has to be broken for repairs
between the tank and skid. The shutoff valves can be closed, thereby eliminating the need
to drain the tank before making repairs.

20. Install, clean and fill the foam concentrate storage tank in accordance with the
rnanutacturer's recommended procedures.

21. Fill the foam concentrate piping with foam concentrate.

22. If applicable, check the relief valve for proper installation. See manufacturer's instructions.

23. Run a pump pressure output and relief valve pressure setting check as follows:

a. Starting with all valves in their normal standby position, open valves "A", "B" and "C" and
close valve "L".

b. Start foam concentrate pump; concentrate will recirculate back to foam tank.

c. Slowly close valve "C" and observe the red pointer on the duplex gauge until it shows a
sudden decrease. This will indicate opening of the relief valve. Adjust setting if required.

24. Return all valves to standby position and proceed with full system test as described in
Section 2-4, Testing Afier Installation in this manual.

2-3 INSTALLATION AND START-UP: SYSTEM SUPPLJED AS LOaSE COMPONENTS

NOTE: When system is supplied as loose components refer to the individual component's
manual forinstallation instructions.
NOTE: Although Chemguard offers skid units as shown in Fig. 2-1 and Fig. 2-2, when system
component parts are supplied as loose equipment, the customer may choose not to arrange
the components in a skid type unit but rather in their own individual piping configuration.
However, installation instructions in this manual must be followed to insure proper system
operation and to prevent possible system failure.

CHEMGUARO,M: 204 S. 6th Avenue • Mansfield, Texas. USA 76063 • (817) 473-996<1 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTlONING SYSTEM 2-7

O CAUTION: For proper piping sizes, eontaet Chemguard Engineering.

O WARNING: Automated Foam Fire Proteetion 5ystem -In an Automated Foam

Fire Proteetion System where manually operated valve(s) are used in the foam
solution line from the proportioner to the diseharge deviee(s), Chemguard
strongly reeommends that all manual valve(s) be ehained or loeked in the
open position or equipped with tamper alarm switeh(es) whieh are monitored
by a supervisory panel alarm.

Chemguard, Ine. is con cerned about the possibility tl1at any manually
operated valve(s) in the foam solution line to the hazard(s) eould inadvertently
be left in the elosed position during a fire eondition, whieh would prevent the
foam solution from reaehing the hazard(s) in the event of an automatie trip
sequenee.

1. If applieable, follow Sect. 2-2, Skid Mounled Proportioning Syslem, ílem A, Sile Seleelion
procedures.

2. A minimum of five (5) pipe diamelers of slraighl unobslrueled pipe is required upslream and
downslream of eaeh ralio eonlroller.

3. AII inlereonneeling piping musl be self-supported. Plaslie foam eoneenlrale slorage tanks
musl have flexible eonneelion fittings inslalled between lhe lank and proportioning
equipmenl lo eliminale slress imposed by lhe piping and lo eliminate lhe effecls of vibralion.

4. For Chemguard reeommended eomponenls - valves, slrainers, gauges and eonneelions,

and their locatlon in lhe syslem, refer lo lhe Operaling Sehemalie Drawing, Fig. 3-1, page
6-3.

5. Proportioning syslem slrainer mesh shall have 1/4" openings for alcohol resistanl foam
concentratss and 1/8" openings for all other foam eoneenlrales.

6. If applieable, lhe foam eoneenlrale and waler sensing lines lo lhe diaphragm valve rnust be
a minimum 3/16" 1.0. pipe and lubing.

7. The diaphragm valve musl be mounled in the proper posilion.

8. Follow reeommended procedures 6 thru 24 for skid mounted proportioning systems where
applicable. -

NOTE: Reference Sect. 2-2, item 19 - when the syslem is supplied as loose eomponents, it may
be desirable lo position valves A and B at the foam eoneentrate storage tank, between the tank
and lhe flexible eonneelions. This may eliminate the need for valves A and B plus shutoff valves in
the suetion and return piping. However, the need for valves A and B in place of tank shutoff valves
will have lo be evalualed on an individual system design basis. For questions or problem solving,
contact Chemguard, Ine. Engineering Department.

9. Inslall a Ball Drip Valve following the procedures outlined below:

CHEMGUARDJNC 204 S. 6th Avenue • Mansfield, Texas. USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - - BALANCED PRESSURE PROPDRTlDNING SYSTEM 2-8

9. Install a Ball Drip Valve following the procedures outlined below:

Ball Drip Valves are used on a Balanced Pressure Proportioning System as an automatic
low point drain between the ratio controller and the water shutoff valve. l.lquld which
remains undrained between the ratio controller and the water shutoff valve could cause
pipe corrosion in this area. Also, if líquld is present in this area, the possibility of freezing is
another potential problem.
FOAM
WATER CONCENTRATE
A. Installation SHUTOFF VALVE WATER SUPPLY
TO
¡

·=
DRAIN 1 .

~~~ d::uum}:ium~:::"
= '
) CONTROLLER
BAlL DRIP VALVE .

PIPE
NOTE:
BALL DRIP VALVE MUST BE /NSTALLED
IN THE HORIZONTAL POSITION.
.Q
"...
\
. ./'7
3/4" THREADOLET

,¡:----.//
~
~
l
WELD ro 80rrOM OF PIPE
• 3/4" ELBOW (LOW POINT)
B. Maintenance .:f
no maintenance required ~ BALL DRIP VALVE

2·4 TESTING AFTER INSTALLATION

1. The completed system shall be tested by qualified personnel to meet the approval of the
authority having jurisdiction. These tests shall be adequate to determine that the system
has been properly installed and will function as intended. (NFPA 11, para. 6-3*,
Acceptance Test, latest edition)

2. Foam systems shall be examined visually to determine that they have been properly
lnstalled. They shall be inspected for such items as conformity with installation plans;
continuity of piping; removal of temporary blinds; accessibility of valves; controls, and
gages and proper installation of vapor seals, where applicable. Devices shall be checked
for proper identification and operating instructions. (NFPA 11, para. 6-1, Inspection and
Visual Examination, latest edition)

3. Beforeacceptance, all operating devices and equipment shall be tested for proper function.
(NFPA 11, para. 6-3.2, Operating Tests, latest edition)

CHEMGUARD,N:: 204 S. 6th Avenue • Mansfield, Texas, USA 76063 • (817) 473·9964. FAX: (817) 473-0606
- - - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTlONING SYSTEM 2-9

4. A full scale test shall be conducted after the system is installed and prior to acceptance of
the system. The test run shall include running water to each discharge device to insure that
proper pressures and flow rates can be achieved and to insure there is no blockage. Then
foam solution shall be run to the devices protecting the greatest singlehazard and to the
device with the lowest flow rate. The foam test shalllast a minimum of one (1) minute -
actual injection time - to insure the proportioning system has stabilized before taking
samples. At this time, the quality of the foam shall be observed and the foam solution
concentration shall be checked by the refractive index method. Conductivity measurement
is an acceptable alternative, consult Chemguard, Inc. Engineering Department for
additional assistance. The foam test shall be conducted for each ratio controller when
multiple proportioners are present in the system. See NFPA 11 tor detailed procedures.

5. Afier completion of acceptance test, the system shall be flushed and restored to
operational condition. (NFPA 11, para. 6-4., System Restoration, latest edition)

CHEMGUARD"
INCORPORATEO

rHEMGUARD,~ 204 S. 6th Aven"• • Manslield. Texas. USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 3·1

CHAPTER 3 - OPERATING PROCEOURES

3-1 OPERATlON OF MANUAL SYSTEM

1. Verify that all valves on the proportioning system are in their normal stand-by position.
Referto Operating Schematic Owg. Fig. 3-1.

2. Open the appropriate foam solutlon zone discharge valve(s).

3. If an auxiliary pump is provided, open appropriate pump suction vale "B1" or "B2".
NOTE: If the system ls automated, both valves "B1" and "B2" shall be open.

4. Verify that the diaphragm foam concentrate discharge valve "L" is in the open position.
This valve shall be open when the system is in its stand-by status.

5. Start the foam concentrate pump and observe the duplex gauge to be sure the foam
concentrate pump is building some pressure on the duplex gauge.

6. Open the water supply valve.

7. Open the foam concentrate discharge valve "O". If more than one proportioner is
provided, open appropriate discharge valve "O" to the corresponding proportioner. Verify
that pointers on the duplex gauge are balancing; if not, follow the procedures under
Manual System Override below.

3·2 MANUAL. SYSTEM OVER·RIOJE (MANUAL REGULATION)

In the event that the diaphragm valve fails, indicated by an imbalanced pressure on the duplex
gauge, the system can be balanced manually (Referto Operating Schematic Owg. Fig. 3-1):

1. Close the foam concentrate discharge valve "L" adjacent to the diaphragm valve.

2. Open the manual foam concentrate bypass valve "C".

3. Adjust valve "C" to maintain equal pressure on the duplex gauge.

NOTE: The manual concentrate bypass valve "C" is adjusted by either opening or closing
valve "C" and observing the Red Pointer (Foam Concentrate) and Black Pointer (Water) on the
duplex gauge. The system is balanced when the concentrate pressure corresponds to the
water pressure.

WARNING: Any change in system flow or operating pressure, when operating

o in "Manual" mode will require the readjustment of the Manual Concentrate
l:lypass Valve "C".

rHEMGUARD,~ 204 S. 6th Aven"e • Manstield. Texas. USA 76063 • 1817) 473-9964 • FAX: 1817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTlONING SYSTEM 3-2

3-3 SHUTDOWN

1. Close the foam concentrate discharge valve(s) "D".

2. Shutdown the foam concentrate pump.

3. Allow the water to run until clear water discharges from the devices being operated.

4. Close the water supply valve or valves.

5. Place the foam solution zone discharge valve(s) in their normal stand-by position.

6. Afier flushing system solution piping, remove all strainer screens and clean. Reinstall
screens afier cleaning.

7. Return all valves to their stand-by status. Refer to Normal Stand-By Valve Position Chart
on Operating Schematic Dwg. Fig. 3-1.

8. Replenish supply of foam concentrate. If the tank is empty, it should be inspected to

determine if cleaning is warranted before refilling. If cleaning is judged necessary, refer to
manufacturer's instructions. If a storage tank is provided by Chemguard, refer to
Chemguard Storage Tank Installation, Cleaning & Filling Instruction Manual for
recommendations.

o CAUTION: Only foam concentrate ot type Iisted on the tank nameplate should
be used to replenish the tank. Mixing of different types of foam concentrates
could cause failure of the system.

9. Replace all frangible components such as glass diaphragms, ruptured disc, etc., in foam
lines or foam making devices.

3-4 AUTOMATIC OPERATION OF SYSTEM

For automated systems, refer to the Automatic Operation or Control Panel section of the
Operating and Maintenance Manual for automatic operation and sequence.

CHEMGUARo.
INCORPORATED

CHEMGUARD,Nt: 204 S. 6th Avenue .. Manslield, Texas. USA 76063 • (817) 473-9964 .. FAX: (817) 473-0606
- - - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 3-3
3-5 MINIMUM INLET PRESSURE REQUIREMENTS

Since it is no! uncommon for water inlet pressures to be quite low in sorne systems applications, re"
is necessary to determine that the minimum proportioning system inlet pressure is adequate to
allow proper system operation. The curves in Fig. 3-2 indicate the minimum inlet pressure
required relative to the anticipated flow rate of the system. These curves apply to all proportioning
systems which utilize Chemguard ratio controllers.

PSI
1
'00
19:]
1
lOO 1
110
1
lOO
6" B"
'''' 4"
'''''
lJO 1 1 1
21/2" 1 3"
1m
110 1
~ 100
1 1 1 1 1
1 11
¡¡J
en '" I
w ao
a:
o. 70
11 1/
1
I:i:i '" / 1/
~ fiJ
/
ffi 40
V / / 1/
1- JO
~ 20
10

~ lOO W ~ ~ ~ ~ ~ 1~ ~ ~ ~ ~ ~ Q~

SOLUTION FLOW

FIGURE 3-2
RATIO CONTROLLER MINIMUM INLET PRESSURE VS. SOLUTION FLOW CHART

CHENfGUAB.D
INCORPORATEO

CHEMGUARDINC. 204 S. 6th Avenue • Mansfield, Texas. USA 76063 • (817)473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTlONING SYSTEM 4·1

CHAPTER 4 - INSPECTION ANO MAINTENANCE

4-1 INSPECTION ANO MAINTENANCE

See Table 4-1 far recommended inspection and maintenance procedures. These
procedures and recommended intervals are based on normal operating conditions and
may have to be modified to meet the existing conditions.

.. WARNING: The intervals in this chapter are a general recommendation; some

environmental conditions may dictate such inspections and maintenance be
pertormed at more frequent intervals.

.. CAUTION: When cycling automated valves, make sure the main water valve,
Foam Concentrate Suction Valve "B" and Return Valve "A" are closed. After
cycling, return all valves to their normal standby position.

.. CAUTION: The Foam Concentrate Oischarge Valve(s) "O" must be closed

when circulating foam concentrate through the proportioning system to
prevent loss of foam concentrate. Refer to Operating Schematic Owg. Fig. 3-1.

For various proportioning system components (diaphragm valve, foam concentrate pump,
valves, actuators, etc.) refer to that particular component's operating and maintenance
manual or instruction sheet far inspection and maintenance procedures.

4-2 TESTlNG 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 insure proper operation before being placed back into
service.

NOTE:

The services of a qualified field engineer to inspect the system and run the test for start up and
the annual inspection can be provided. Additional details can be obtained by contacting the
Chemguard, Inc. Service Department.

Chemguard, Inc. Service Department Telephone: 817-473-9964

204 S. Sixth Ave. Fax: 817-473-0606
Mansfield, Texas 76063 USA E-mail: info@chemguard.com

If testing of the system for initial start-up is performed by other than Chemguard, Inc. personnel,
please forward a copy of the test report or letter stating that the system performed satisfactarily, to
Chemguard Inc. Service Department.

CHEMGUARD,M: 204 S. 6th Avenue • Mansfield, Texas, USA 76063 • (817) 473·9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 4·2
4-3 ANNUAL TESTING

No less than annually, all foam systems shall be thoroughly inspected and checked for proper
operation. This shall include performance evaluation of the foam concentrate or premix
solution quality or both. Deviation of results exceeding 10% from those recorded in acceptance
testing shall be discussed immediately with the Chemguard, Inc. Service Department. Regular
service contracts are recommended. The goal of the inspection and testing shall be to ensure
that the system is in full operating condition, and that it will remain in that condition until the
next inspection. The inspection report, with recommendations, shall be filed with the owner.
Between the regular service contract inspections or test, the system shall be inspected by
competent personnel following an approved schedule. (NFPA 11, para. 7-1, Periodic
Inspection, latest edition)

TABLE 4-1 - BECOMMENDED INSPECTION & MAINTENANCE SCHEDULE

NOTE: The following recommendations are based on normal operating conditions. Due to
environmental or other conditions unique to your system, the frequency of sorne inspection and
maintenance procedures may need to be adjusted. Additional inspection and maintenance
procedures may also be required.

NOTE: When performing inspection and maintenance procedures which:

a. require operation of the system or parts of the system,

b. cause the system to be non-operational during the procedure,
c. cause a trouble indication, the system should be taken out of service
and the proper authorities should be notified.

CHEMI.';UARDJIIJC. 204 S. 6th Avenue .. Mansfield, Texas, USA 76063 .. 1817) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSUREPROPORTlONING SYSTEM 4·3

AFTER SEMI· NOTES

DESCRIPTION START-UP OPERATION WEEKlY MONTHlY ANNUAL ANNUAL

•
Check all valves to insure that they are in the
normai slandby conditlon. See System
O eratin Drawin Fi . 3·1
2. Inspecl system for h slcal damage and re airo
3. Check lhe complele systern, all vaives, filtings &
connections for leaka e.
4. Perform normal maintenance and inspection of
Ihe fire waler supply syslem lo Insure Ihat 11 wili
be o erational when re uired.
5. Perform Ihe after Inslallation lesl as prescrlbed in
Cha ler 2 Sec!. 2·4 01 Ihis manual.
6. Perfarm annual syslem test as prescrlbed in lhe
Cha ter 4, Sec!. 4·3 of lhis manual.
7. Flush proportioning system. See flushing Afier mainlenance
inslructions Chapler 4, sect, 4·14 of thls manual lopipIDg
8. Cele automaled valves where raclical.
9. Circulale Ihe foam concenlrale.

CAUTION: The foam concentrate

o discharge valve(s) "D" must be closed

to preventloss of foam concentrate.

NOTE: When the foam concentrale is

circulatin ,veri au es are functionin
10. Check !Iange bolts for tighlness.
11. Check syslem far any external damage lo the
painl surtaces.

1. Service um and motor.

2. Check allgnmenl 01 pump, reducer and molar.
See Manufaclurer's data for delails.
3. Lubrfcale pump, reducer, and molar in accordance
with manufaclurer's lnstructlons
4. Check pumps, molars, reducers, diesel and
asoline en ines for ro er olllevel.
5. Check that Ihe proper voltage is available to
um motor.
6. Check molar for proper rotallon. Rolate pump
b hand lo insure freedom of movemen!.
7. Run pump lo insure proper operalion. Check lar
leakage, excesslve noise or vibration or overheating
in lhe um • reducer and molar.
8. Check that Ihe pump will supply adequate pressure
lo su I s slem.
9. Check relief valve seltlng for proper operation.
See Sec!. 2·2 Item 23. Refer lo mfg's dala far
rellel valve seltin rocedures.
10. Service diesel or asoline en Ine drfver.

rHEMGUARD,~ 204 S. 6th Avenue • MansHeld, Texas, USA 76063 • (817) 473·9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTIONING SYSTEM 4-4

DESCRIPTION START·UP OP~~~~ON WEEKLY MONTHLY A~~~~L ANNUAL NOTES

11. Run englne exclusive 01 pump.

NOTE: II no clutch is provided, recirculate
loam concentrate back lnto storage tank

Cycie valve(s) - Valve(s) may be cycled Irom

control panel or by manual override at valve.
NOTE: When cycling loam concentrate valves,
be sure that the suppiy and return valves at the
tanks are closed to prevent ioss 01 loam concentrate
or possible dilution II there is water in the line.

o WARNING: When automaled val ves are

cycled, the mal n water supply valve musl
be closed.

2. Cycle the valvets) lrom the control panelto ínsure

ro er o erallon Irom control.
3. Check su ervislon 01 control clrcult,
4. Check lor leakage past valve sea!.
••• • : 1

o WARNING: When water powered ball

valves are eycled, loam concenlrate
supply Valv", "B" musl be closed.

1. Cycle valveís) eilher manually or through

control anel.
2. Cycle the vaive(s) uslng the soienoid release (11
a Iicable.
3. Check supervislon 01 circuil il solenoid reiease
Is rovided.
4. Make sure the drain!vent valve Is lully closed.

, .. I

1. Cycle valves(s) • Valve(s) may be cycled

lrom control panel or by manual override at valve.
NOTE: When cycllng loam concentrate valves,
be sure that the supply and return valves at the
tanks are closed to prevent loss olloam concentrate
or posslble dilulion il there Is water in the line.

o WARNING: When autemated valves are cycled,

lhe maín water supply valve musl be clesed.

2. Cycle valve(s) lrom control panel to lnsure

ro er o erallon lrom control.
3. Check su ervislon 01 control clrcui!.
4. Check air su l.
5. Check iow alr su I alarm,
6. Check lor ieakage past valve seat,

D!mil
Inspect the pressure vacuum vent to insure
that the poppets move Ireely, the screens are clean
and there Is no other dirt or blocka e.

rHEMGUARD,~ 204 S. 6th Avenue • Manslleld. Texas, USA 76063 • (B17) 473·9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - - BALANCéD PRéSSURé PROPORTlONING SYSTéM 4·5

AFTER SEMI· NOTES

DESCRIPTION START·UP OPERATION WEEKLY MONTHLY ANNUAL ANNUAL

2. Service pressure vacuum ven!. Reler ta

Chemguard manuals far recammendatians
far Chemguard supplied lanks.

•
Check the levei 01 cancenlrate In the tank.
Plasllc tanks do nal require a speciflc expansian
dome, bul shauid have a suilable allawance far
faam expansian and cantracllan. Steel and
s!ainiess steel tanks shauld be filled lo lhe mid
painl af lhe expansian dome. Reler lo Chemguard
manuals lar recammendatians far Chemguard
su lIed tanks.
2. Service the pressure vacuum venl in accardance
wilh lnstructlons aullined Sec!. 4-10 01 this manual.
3. Check lar rusl, carrasian, leakage, and weak
soots ar ather h sical dama e.
4. Check paly lank fianged fittings far leakage.

1.
•
Check lhal starage temperalure is wilhin
acceplable Iimils. Reler lo Chemguard
manuals far recammended lemperalures far
Chem uard laam cancentrale.
2. Sample laam cancentrate and submit sampie ta
laam manufacturer lo be lested lar sedlmentatian,
carrasian, dllutian, ar cantamlnalian. Refer ta
Chemguard manuals lar sampllng Inslrucllans.

•
1. Check lhal proper indicatars are presen!. See
control anel data.
2. Check su ervisian af all circults.
3. Check alarm o eratians.
4. Check s slem o erallans.
5. Check thal all indlcalars IlIuminate.

4·14 FLUSHING - FOAM CONCENTRATE PIPING

NOTE: Flushing is to be done only prior to refilling a depleted tank, changing type of foarn
concentrate, or if the foam concentrate piping has to be broken for repairs.

o CAUTION: If the tank is fuH of foam concentrate, the Tank Suction Valve "B" and Return
Valve "A" must be closed to prevent dilution of the foam concentrate.

NOTE: Refer to Operating Schematic drawing Fig. 3-1 for identification and location of
system valves.

1. Close foam concentrate tank supply valve "B" and foam concentrate tank return valve "A".

2. Close foam concentrate discharge valve(s) "D". Close all other proportioning system
valves.

CHEMGUARD,M: 204 S. 6th Avenue _ Manslield. Texas, USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTlONING SYSTEM 4-6

3. Attach water supply to Flush-In Connection "S".

4. Attach hose to Flush-Out Connection "T".

5. Open petcock (concentrate chamber flush out) on diaphragm valve.

6. Open valve "C". Open valves "B1" and "B2" if provided..

7. Open water supply valve.

8. Start foam concentrate pump.

a. Momentarily close manual concentrate bypass valve "C"; open and close several times.

b. Open valve "L" and close valve "C".

9. Momentarily open the duplex gauge concentrate flush-out petcock, the duplex gauge water
ñush-out petcock and the foam concentrate discharge valve(s) "D". Then close petcocks
and valve(s), if available.

10. Flush until water runs c1ear.

a. Stop concentrate pump, open the plugged connection on Strainer Flush-Out Connection
"U" and then close water supply valves.

b. Let system drain through Strainer Flush-Out Connection "U" and Flush-Out Connection
"T" remove strainer and clean. Close Strainer Flush-Out Connection "U".

c. Remove lower plug in concentrate pump, allow to drain and replace the plug.

d. Open all low point drains, allow to drain then close drains.

e. Remove all system strainers and clean.

f. Return all valves to their normal stand-by position, Refer to Operating Schematic Dwg.
Fig. 3-1 with valve position chart and "stand-by" status.

11. Recirculate the foam concentrate briefly to insure that all air is removed from the
concentrate piping.

CHEMGUARD,Nr:. 204 S. 6th Avenue • Mansfield. Texas, USA 76063,. (817) 473-9964 • FAX: (817) 473-0606
- - - - - - - - - - - - - - - - - BALANCED PRESSURE PROPORTlONING SYSTEM 5-1
CHAPTER 5 • TROUBLESHOOTING

5-1 TROUBLESHOOTING INTRODUCTION

See Table 5-1 for Troubleshooting Problems, Possible Causes and Corrective Actions.
These procedures cover problems that may be experienced during normal operations.
Although these recommendations cover most problems that are experienced, there are
some situations that may occur which are not covered in these instructions. Please contact
Chemguard's Service Department for problems that cannot be resolved through the use of
this manual.

Chemguard, Ine. Serviee Department Telephone: 817-473-9964

204 S. Sixth Ave. Fax: 817-473-0606
Mansfield, Texas 76063 USA E-mail: info@ehemguard.eom

NOTE: Refer to individual instruction manuals or sheets for additional information on system
components and discharge devices.

TABLE 5-1 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTlON

5·2 No Tank Return Valve "A" and Tank Suction Check valve position on tank to insure
Proportioning Valve "B" at loam concentrate tank not that they are lully open. Open Valve(s) il
open. closed.

Manual Foam Concentrate Discharge Fully open valve (Normal stand-by

Valve "D" not open. position is Closed).

Automatic Foam Concentrate Discharge Check that wiring is installed to actuator.

Valve "D" Closed. (Electricallyactuated)

Check that signal Irom control system is

available atvaive actuator. II voltage is
not present, check control system

II signal is present at actuator, use

manual override to cycle valve. tI valve
cycies manually, then valve actuator is
probably delective. Remove actuator,
check operation, il inoperative, repair or
replace. II valve does not open, using
manual override on actuator, the valve is
jammed. Remove valve, determine and
correct reason lor jamo See actuator
data.

CHEMGUARD,M: 204 S. 6th Avenue • Manslield. Texas, USA 76063 • (BiT) 473-9964 • FAX: (817) 473·0606
 BALANCED PRESSURE PROPORTlONING SYSTEM
TABLE 5-1 TROUBLESHOOTING
PROBLEII/I POSSIBLE CAUSE
5-2 No Aulomatic Foam Concenlrale Discharge
Proportioning Valve "D" closed. (Water Powered Ball
(continued) Valve)
Foam pump relief valve selloo low.
Ouplex gauge will show foam concenlrale
pressure lower lhan waler pressure.
Pressure in foam concenlrate line will
probably pulse.
Manual Concenlrate Bypass valve "C"
open (Diaphragm valve).
Foam concenlrale fiushing valve open or
partially open. (Oiaphragm valve)
Orain valves in foam concentrate piping
open or partially open.
Control system nol functioning properly.
Concentrate not compatible with the
system.
Slrainer clogged. High vacuum reading on
compound gauge. Pump will probably be
very noisy due to cavitation.
Wrong size strainer basket.
Water pressure loo high. Pump cannot
build sufficient pressure lo overcome
water pressure.
CHEMGUARD,fJC 204 S. 6th Avenue • Mansfield, Texas. USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
5-2
CORRECTIVE ACTION
Check that cylinder water pressure supply
valve is fully open.
Check OrainNent valve on strainer for
clogging which shuts off water supply lo
cylinder. Open OrainNenl valve on
stralner, venl and f1ush any debris
blocking waler supply.
Foam concenlrale allowed lo bypass
lhrough relief valve al pressure lower
lhan waler pressure on supply line lo ralio
conlroller. Resel pump relief valve to
correcl pressure.
Check that manual bypass valve for
diaphragm valve is closed complelely.
Ouplex gauge will show foam concéntrate
pressure lower lhan waler pressure.
Check to insure flush valves are closed.
Ouplex gauge will show foam concentrate
pressure lower than water pressure.
Check to insure f1ush valves are closed.
. ,....
Check wiring for correct inlerconnection
and proper connections. See control
system manual.
Use correct concentrate. Oraln and clean
tank before filling with new concentrate.
Blow down, remove strainer screen and
clean.
Replace with proper size strainer basket.
Reduce water pressure to system
IImilations. Reset pump relief valve 25
psi higher than water pressure, provided
pump motor has sufficient horsepower to
drive the pump at a higher pressure
rating.
 BALANCED PRESSURE PROPORTIONING SYSTEM 5·3

TABLE 5·1 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

5·2 No Low water pressure. Insufficient Delta P. Increase water pressure. Contact
Proportioning Chemguard Englneering Department lor
(continued) recommendations.

Foam concentrate storage tank empty. Fill tank. See manulacturer's instructions.

Water sensing line clogged. Remove senslng line. Clean or replace.

Clean water senslng orlllce in ratio
controller.

5·3 Low Percenl of Tank Suction Valve "B" alloam Check valve posltlon. Normal standby
Proportioning concentrate tank partially open. Pump posltlon ls lully OPEN.
should be nolsy due to cavltation.
Compound gauge willlndicate high
vacuum.

Manual Foam Concentrate Dlscharge Fully open valve. II syslem has dual
valve(s) "D" not lully open. Posslbly proportloners, be sure second discharge
blocked. valve lor proportioner not being used is
closed.

Automatic Foam Concentrate Discharge Determine cause and correct.

valve(s) "D" not lully open. Possibly
blocked.

Automatic Foam Concentrate Discharge Cylinder water pressure supply valve

Valve "D" opens slowly. (Water powered partially open. Fully open valve.
ball valve)
Tlghten DrainNent valve on cylinder
strainer. snug wlth wrench to insure
closure to rated pressure.

DrainNent valve clogged, obstructing

water supply to cylinder. Open
DralnNent valve on stralner
and vent. Flush any debris blocklng
water supply.

Foam concentrate pump not operating to Loss 01 phase motor.

capaclty.
Low vollage to motor.
o

Check pump end clearance.

Check lor damage to vanes, gears andlor

pushrods. See manulacturer's data.

Manual Concentrate Bypass Valve "C" Check that bypass valve is completely
partially open (Diaphragm Valve). Duplex closed.
gauge will Indlcate low pressure.

CHEMGUARDIA.'C- 204 S. 6th Avenue • Mansljeld, Texas, USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
 BALANCED PRESSURE PROPORTIONING SYSTEM 5-4

TABLE 5·1 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

5·3 Low Percent 01 Water pressure exceeds the design limits Adjust pressure to proportioner to be
Proportioning 01 the system. System requires more within Ilow and pressure limits 01 the
(continued) capacity than pump ts capable 01 system.
producing.

Flush-In Conneclion "S" open or partially Check to insure all Ilush connections and
open. Duplex gauge will show loam valves are closed.
concenlrate pressure lower than water
pressure.

Drain valves in loam concentrate piplng Check lo insure all drain valves are
open or partially open. Duplex gauge will closed.
show loam concentrate pressure lower
than water pressure.

Conlrol system not lunctioning properly. See control system manual. Check
wiring lor correct interconnection. Check
wiring lor proper connections.

Foam concentrate strainer clogged. High Remove strainer screen and clean.
vacuum reading on compound gauge.
Pump will probably be very noisy due to
cavitation.

Diaphragm valve not lunctioning properly. Check water sensing lines lor blockage.
Duplex gauge will not show balance. Make sure that there are no air pockets in
lhe water senslng IInes.

Diaphragm Valve water drain petcock Fully elose water drain petcock.
open.

Foam concentrate incompatible with Use only loam concentrates tor which
system designo the system was designed. Contact
Chemguard lf you are changlng loam
concentrates.

Incorrect orifice dlameter. Contacl Chemguard's Service

Department lor instruclions on checking
orilice.

--

CHEMGUARD,= 20< S. 6th Avenve • Mansfietd. Texas. USA 76063 • (817) 473-9964 • FAX: (817) 473-0606
 BALANCED PRESSURE PROPORTIONING SYSTEM 5-5

TABLE 5-1 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

5-4 High Pereent 01 Tank RelumValve"A" al loam eoneenlrale Check valve position lo insure Ihal Valve
Proportioning lank nol open. "A" is open. Openvalve il closed.

Foam Concenlrale Discharge Valve "L" lo Open Valve "L" lo allow diaphragm valve
diaphragm valve closed. lo lunclion.

Diaphragm valve nol funclioning properly. Check loam concenlrale sensing Iines lor
Duplex gauge will nol show balance. blockage. Make sure Ihal Ihere are no air
pockels in Ihe loam concenlrale sensing
Iines.

Diaphragm Valve loam concenlrale drain Fully close drain pelcock.

pelcock open.

Foam concenlrale incompalible wilh Use only loam concentrares lor which Ihe
systern designo syslem was designed. Conlacl
Chemguard il you are changing loam
concentrates,

Incorrecl orilice diameler. Conlacl Chemguard's Service

Departmenl lor inslruclions on checking
orilice.

Waler flow loo low lor ratio conlroller. Check syslem pressure. II low, lind and
correcl problem.

Blockage in solution line or valves nol

complelely open. Check solution line and
correcl.

Discharge device blocked. Check

devices and correcl problem.

Foam concéntrate sensing line clogged. Remove sensing line and clean or
replace. Clean loam concenlrale sensing
orilice in ralio conlroller.

Waler supply valve closed. Open valve. II aulomaled, locale reason

5-5 No Flow at
and correel.
Diseharge Deviee(s)
Fire pump did nol start, Delermine Ihe cause and correcl Ihe
problem. -

Blockage in Ihe waler supply or loam Find Ihe cause ollhe blockage and
solution discharge line. correcl.

Manual valves in solution plping shut or Check line lor blockage or open manual
blockage in line. valves.

CHEMGUARDwt:. 204 s. 6th AvenuE _ Mansfield, Texas, USA 76063 • (eH) 473·9964 • FAX: (eH) 473-0606
 BALANCED PRESSURE PROPORTlONING SYSTEM 5-6

TABLE 5-1 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

5-6 Low Flow at System pressure too low. Check inlet pressure and correct for
Discharge Device(s) proper operation.

Fire pumps did not start. Determine

reason and corree!.

Partial blockage in water or foam solution

line.

Zone valve did not open completely.

Valve jammed, determine reason and
corree!.

5-7 Foam No power or incorrect voltage. Check that power is available and correct
Concentrate Pump voltage is available to all three motor
not Running legs.

Check that wiring is complete to the

pump.

Check that all disconnect switches and

circuit breakers are closed, and fuses are
in satisfactory condition.

Pump couplings disconnected at reducer Connect couplings following man- ,..

,"

or pump. ufacturer's instructions.

Reducer jammed or damaged. Determine cause and corree!.

Pumpjammed Determine cause and corree!.

Foam concentrate pump running wrong Reverse rotation of foam concentrate

direction. pump. See manufacturer's data.

Pump operational problems. See manufacturer's data or contact the

Chemguard Service Departmen!.

5-8 No Operation Power failure Check power source and correct problem.

Control system not functioning properly. Check wiring for correct interconnection
and proper conneclions. See control
system manual.

Foam concentrate storage tank empty. FiII tank. See manufacturer's instructions.

Failure of water supply system. Check water supply and correct problem .

CHEMGUARDJNt: 204 S. 6th Avenue ID Mansfield, Texas, USA 76063 ID (aH) 473-9964 ID FAX; (817) 473-0606
 pllpLEX gAUGE
NORMAL STAND·BYVALVE POSITION CHAAT mOf.l PROPOATlONER FROY PROPORTIONER
WATER PRESSURE WATER enassuna RED POINTER - FO"'" CONCENTRATE
:r: POSIllON EN51 BLACK P01NTER • WATER

~
VlLVE DESCRII"JlON
Fo.w COhCENlRA.TE TNI<RETURN
DESIGNAnON
A
IIANUlL
OPEN
AUTO.
OPEN "NID.~r _ í-.J- : 1'O ",
~
l:i
Fl),IJ,I (XH;EHTRATE T.w<SUCOON D
e
OPEN OPEN
TODW'tIRAGU V,tlVE >~ SHumE CHECK
UANUAl CONCENTRATE BYPASS ClOSEO CLOSED WATER CONNECTION' L''- REaUIRED WHEN lWO
Ii"'

~
¡
fOAIoI CONCENTRATE 0I5CHARGE
fOAll CONCENTRAre DISCIIARGE
D
L
ClOSED
OPEN
CLOSED
OPEN
PROPORnONERS ARE USED
DETAlL -P-
FlUSH.Qur :>- <FLUSH.QUT

SENSINGCONNECTlONS WATER
10 DIAPHRAGU VAlVE

I~::"~~
FORDUALPAOPOATIONEAS
ro
FlUSH·IN CONNECTION
nusaeut CONNECTIOH
•
T
ClOSED
CLDSEO
ClOSED
CLOSED "LV'
~
fI'
STRAIHER FLUSH OUT U CLOSEO ClOSEO
f
•
1·~ ~
FOil... CONC.
',USH·OUT

~
OAM CONCENTRATE STORAGETANK
'"
s
DlAPHRAGU VAlVE WATER
R..USH.()UT
CLOSED ClOSEO
.. CONC. CH......8ER
<
»
ro
DlAPHRAGU VALVE COHCENTRATE
FLUSH.(]UT
CLOSED CLOSEO
~ PRESSUREVACUUM va«

INSPECTIOH HATCH t L r\::-FLUSH.QUT VAlVE

WATER SEHSING UNE
"e
ro ORAlN VAlVES CLOSED CLOSEO
FO......COHCENTRATE BEH51NG UNE
FU CONNECTlON
• WATER SUPPLY YAlVES CLOSED ClOSED PETAn -,,-
SENSING L1NES
s: FOAU SDlUTlON lONE VAlVES ClOSED ClOSED ~
ro
""ro·'- fOAI,l CONCENTRATE TAN< 5lJC1lCH DI OPEN OPEN ~~
(pRIUARf Pl/UPI 'o ~~""­
~Q"""

~
CONTRO~ER
L"'l~·
¡;: FO.W CONCENTRATE fAltl: SUCT10H ClOSED 4:l RATIO""t.- R

ro' (AUXlUARY PWlPJ

" OPEN
<t'!';'
PROPORTlONE
WATERVI>J.VE
x FOAU CONCENTRAn. D1SCHARGE D CLOSED CLOSED
/')I~~
1:\"" 1/
~
ro
',.een" (SECONO PRDPDRTlONERJ
s
"'#S'~ ~IK'
~
~
lEGEND
... ~t,'iJ S~~
""
,,' ... - : SéETAlL 'B"\, r
~ ~EX,,>.. í
NO. 1
"
e» SEENO'
.r/ .,.WATER
VAlVE
~
o
en AUfOMATED VALVE

~"r,,---(D) .,,~
w

~
:Jl!./'DIAPHRAGMVAI: , __
•
~."\ ~:::~
§ I><l GATEVALVE lImS: < e-/ GE '{:

."
2! c9<J t. lIems shown dolled are .li-lt"ÑÓrr;NO.

,
BALL VAlVE(N.O.)

~
DpllDnal featulas and are FIELO '"'" AI!TOOIAnc ' '"<>
~
co
<b
..•
m
BALL VALVE (N.C.) nollurnished on 00 syslams. CONNECTlONS -;
- CllPl 1rVALVE
~

~
~
'" ~ MANUAL REGULATING VALVE (N.C.)
2. A1l plplng andvabes In the waler supply
IIna rmd the loam solution dlscJmga lito aro by otharr;. VAlVEV
5EENOTES
-n
» N SWING CHECK VALVE 3. Ifan Aulomallc Foam Concenlrale Dlschsrga Valva "D"
B
rs ".
x. ¡q""
~
is usedon Iha proportionIng S)'slom, the normal sland-by
§ -f«;;+ STRAINER poslUon 01 íhe .MinllAI. F08m Concenlrale Olscha1ge Valva "O" 15 !mJ.D.
:<~ :::!
.
~
2!
D.
"
ce
e COMPOUND GAUGE 4. Supplled wilh Auxllfary Foam Concentrale Pump

5. S1andard localloR 01 "O" Valva (noeUIillary loam cone. pump).

ANTI·VIBRATION
REXIBLE COUPUNG~
"'~

"~ ® DUPLEX GAUGE

AUXUARV lJl
id- FLUSH·IN CONNECTION (MAlE SW.)
6. Locsllon 01 "O" Valva wllh auxlOary foam concenlrala pump. FOAMCONCENTRA.TE~1
PUMP """"
_.
¡;¡
~
FLUSH·OUT CONNECTION (FEM.'SW.)
(OPTIONAlI
ñ1¡¡;:
FIG.3·1
FIElD CDNNEcnON
O OPERATlNG SCHEMATlC DRAWING
'l'
'"