Waterous 200-B Installation & Maintenance Manual Download

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Installation / Maintenance Guide

Applies to Waterous Model

200-B Rev-

BELT-Driven Compressor Kit

FOR INSTALLATION CENTER USAGE ONLY

Waterous, Arizona Operations

7612 North 74th Ave.

Glendale, Arizona 85303

623-979-3398

Fax: 623-979-6949

www.waterousco.com

Summary of Contents for 200-B

Page 1: ...Guide Applies to Waterous Model 200 B Rev BELT Driven Compressor Kit FOR INSTALLATION CENTER USAGE ONLY Waterous Arizona Operations 7612 North 74th Ave Glendale Arizona 85303 623 979 3398 Fax 623 979...

Page 2: ...y waste time and money Revision History Revision Date Issued Comments 08 16 06 Original Release Disclaimer These instructions are guidelines only and in no way meant to be definitive During installati...

Page 3: ...ULIC FILTER INSTALLATION 18 SECTION 8 AUTO SYNC CONTROL SYSTEM INSTALLATION 19 A Manual Valves 19 B Electric Valves Solenoids 20 SECTION 9 BALANCE VALVE INSTALLATION 21 SECTION 10 INITIAL POWER UP 22...

Page 4: ...lter top showing flow direction arrows 18 Figure 22 Auto Sync Manual Valve Assembly 19 Figure 23 Auto Sync Control Switches and Label 19 Figure 24 Typical Air Pressure Gauge 19 Figure 25 Auto Sync Con...

Page 5: ...alternate cooling such as an air oil cooler The compressor kits do not include Drive Components Foam proportioner foam tank foam distribution manifold for CAFS Air water and hydraulic hoses and hose...

Page 6: ...rance for routine maintenance including clearance for checking oil adding oil adjusting pressure changing filters cleaning screens or opening drain valves The sump oil air reservoir can be mounted at...

Page 7: ...fasteners should be checked by the installer prior to operating the unit Caution The air compressor cannot be installed on its side It must remain upright with the air intake on the top A 200 B Compre...

Page 8: ...bolts 16 mm are provided with the compressor kit Bolted to a bracket under the compressor body The bracket must fit between the discharge plate and the oil inject fitting Typically the bracket will b...

Page 9: ...filter If you turn the inlet you will need longer tubing Either acquire colored tubing locally or contact Waterous for the correct lengths and colors To change the rotation of the air inlet disconnec...

Page 10: ...cases finding room for the sump can be difficult It is acceptable to mount the oil sump up to 12 inches higher than the air compressor however this requires the installation of a check valve to preven...

Page 11: ...ressure Relief Sender for Temperature Meter Figure 7 200 B T Sump Side View The sump has mounting holes in the legs Bolt the sump to the pump compartment frame Make sure there is adequate clearance fo...

Page 12: ...of checking oil level and adding oil to the sump Use the supplied plugs to close the unused inlets If the oil sight glass needs to be extended for visibility use rigid pipe to ensure that the level d...

Page 13: ...The smaller prong which is labeled WK may be used to activate an oil temperature warning light or alarm not provided Waterous recommends installing an over temperature device This prong is one side o...

Page 14: ...n the hydraulic and air lines Install it vertically with the housing up the filter element down Make sure there is room to remove and replace the filter element From Sump To Balance Valve and Fixed Ma...

Page 15: ...d Outlet Drain Water Inlet Water Outlet Figure 11 Oil Inlet Outlet Ports Figure 12 Water Inlet Outlet Ports and Drain The oil inlet and outlet may be reversed if it makes installation easier The water...

Page 16: ...fitting OEM supplied from the discharge side of the fire pump see the Hydraulic Schematic The cooling water supply hose should be 1 2 I D for the 200 B to supply the proper flow for cooling the syste...

Page 17: ...ebris or the vehicle relies on drafting for its water supply it may be necessary to install a larger strainer and or a clean out valve on the wye strainer Without good water flow through the heat exch...

Page 18: ...ter Figure 21 Hydraulic Filter top showing flow direction arrows Install the hydraulic filter on the bracket provided as shown in the hydraulic schematic in any available location near the compressor...

Page 19: ...tches and Label Figure 24 Typical Air Pressure Gauge Install the control switch assembly and the master air pressure gauge not included on the pump control panel 1 Turn the control knobs to FIXED and...

Page 20: ...and Label electric Figure 26 Auto Sync valve assembly front electric 1 Install the valves in a convenient location close enough to the pump operators control panel to run the control wires 2 Install...

Page 21: ...rol Manifold Water from discharge side of Fire Pump Figure 27 Piloted Balance Valve inlets and outputs with push on hoses Caution DO NOT use oil or hose clamps on the Auto Sync system push on hoses Th...

Page 22: ...ic oil until the oil level is 1 2 way up the sight glass You will need to add more oil later to compensate for oil that remains in the hydraulic lines and the compressor 8 Oil used in the system is IS...

Page 23: ...E AUTO SYNC AIR BALANCING SYSTEM CAFS retrofit kits and any other system shipped as separate components will need calibrating after installation Note Before you make any adjustments make sure the oil...

Page 24: ...d Balance Trim Valve PBTV 6 Start the fire pump and with the engine at idle establish water flow through a discharge or tank re circulation 7 The main pressure gauge should read approximately 40 PSI w...

Page 25: ...IXED mode must have been correctly set before you attempt to adjust the AUTO mode 1 Make sure the fire pump is operating at 100 PSI at the main discharge with minimal flow 2 Place the controls on the...

Page 26: ...Trim Valve clockwise to lower the pressure until the air pressure is equal to or up to 5 higher than the water pressure 10 Verify the Auto Sync system settings by varying the fire pump discharge press...

Page 27: ...izes If the planned discharge system is not covered in this guideline please contact Waterous Note Waterous strongly suggests that every CAFS discharge have an air check valve and a water check valve...

Page 28: ...circuit because the system air pressure will not exceed 150 psi Also the hose and fittings for hydraulic hose are bulky and expensive Air brake hose may also be used provided the inside diameters are...

Page 29: ...37 JIC swivel to NPT M adapter Delete the following items 8x8 Push Loc 1 8 JIC x NPTM 90 E Suggested for 2 1 2 discharges Use air hose 1 Water Check Valve Suggest wafers or flange style same size as...

Page 30: ...is seldom needs adjusting after the initial setup if the rest of the system is well maintained Note Do not adjust the Auto Sync components to compensate for problems elsewhere in the CAFS system Befor...

Page 31: ...enoid and check operation of solenoid Air discharge solenoid not working Repair replace solenoid Air solenoid working leak between solenoid and discharge Repair leak Air check valve defective Replace...

Page 32: ...evel surface Excess of 200 CFM air flow on 200 CFM systems Back down RPM s and flow CAFS to relieve pressure then recheck Replace Air Oil Separator Filter Air oil Separator Filter torn or damaged coul...

Page 33: ...urned too low foam tank empty Make sure proportioner is turned on foam supply valve is open foam tank has concentrate Y strainer is clean and supply line is connected to injector Discharge hose shakin...

Page 34: ...g compressor to bleed down before engaging clutch again Allow for bleed down Contaminated clutch disc Clean or replace Safety pop off valve opening at low pressure Auto Sync system out of balance Adju...

Page 35: ...un in water until pump is completely filled and all air is expelled 4 Close discharge valve apply pressure to system and watch for leaks or overflowing water tank A pressure of 100 psi is sufficient D...

Page 36: ...umping large volumes of water may produce whirlpools which will allow air to be drawn into intake hose Whenever possible place end of Intake hose at least two feet below water source High point In Int...

Page 37: ...tely into new position will seriously impair pump efficiency Pump Impeller s or wear rings badly worn Install undersize wear rings if Impeller to wear ring clearance is within limits indicated in MAIN...

Page 38: ...are closed Sticky pilot valve Disassemble and clean Replace noticeably worn parts Plugged tube lines Disconnect lines and Inspect Relief Valve Malfunction B Pressure will not return to original setti...

Page 39: ...Waterous 200 B Belt Driven Installation Guide Rev Page 39 of 54 Figure 33 Basic CAFS System...

Page 40: ...Waterous 200 B Belt Driven Installation Guide Rev Page 40 of 54 Figure 34 200 B with T Sump...

Page 41: ...Waterous 200 B Belt Driven Installation Guide Rev Page 41 of 54 Figure 35 200 B with Vertical Sump...

Page 42: ...Waterous 200 B Belt Driven Installation Guide Rev Page 42 of 54 Figure 36 Compressor Dimensions...

Page 43: ...Waterous 200 B Belt Driven Installation Guide Rev Page 43 of 54 Figure 37 T Sump Dimensions...

Page 44: ...Waterous 200 B Belt Driven Installation Guide Rev Page 44 of 54 Figure 38 10 Vertical Reservoir...

Page 45: ...Waterous 200 B Belt Driven Installation Guide Rev Page 45 of 54 Figure 39 Oil Cooler...

Page 46: ...Waterous 200 B Belt Driven Installation Guide Rev Page 46 of 54 Figure 40 200 B Oil and Separator...

Page 47: ...Waterous 200 B Belt Driven Installation Guide Rev Page 47 of 54 Figure 41 Separator Bracket...

Page 48: ...Waterous 200 B Belt Driven Installation Guide Rev Page 48 of 54 Figure 42 Hydraulic Schematic with T Sump...

Page 49: ...Waterous 200 B Belt Driven Installation Guide Rev Page 49 of 54 Figure 43 Hydraulic Schematic with Vertical Sump...

Page 50: ...Waterous 200 B Belt Driven Installation Guide Rev Page 50 of 54 Figure 44 Electrical Schematic for Auto sync...

Page 51: ...Waterous 200 B Belt Driven Installation Guide Rev Page 51 of 54 Figure 45 Air Schematic Electric Auto sync 90 Inlet...

Page 52: ...Waterous 200 B Belt Driven Installation Guide Rev Page 52 of 54 Figure 46 Air Schematic Manual Auto sync Vertical Inlet...

Page 53: ...Waterous 200 B Belt Driven Installation Guide Rev Page 53 of 54 Figure 47 Air Schematic Manual Auto sync 90 Inlet...

Page 54: ...Waterous 200 B Belt Driven Installation Guide Rev Page 54 of 54 Figure 48 Panel Cutouts Electrical Manual Controls...

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