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When you have finished the physical installation of the system, you can begin the start-up procedure, detailed below:
3.O1 Configuring the System Settings
It is necessary to define all the parameters related to the unit, products, channels and washer extractors. Although you can do
this at the front panel, it is easier to use Hydro Connect to configure the unit remotely from a PC.
3.O2 Prime the Hoses that go to the Washer Extractors with Water
The hoses in the delivery channel and from the distribution manifold to the washers need to be filled with water. To do this,
use to the calibration screen and do successive ‘Water’ calibrations to each washer. Also fill the hose that comes back to the
calibration vase by selecting it as the destination. Check for leaks before proceeding to the next step.
3.O3 Prime the Suction Hoses of every Product
The hoses that run from product pick-up drum lances to the collection manifold on the main panel also need to be filled. Once
again use the calibration function but this time select ‘Product’ as calibration mode. You can send the flow to a washer or the
calibration vase, releasing the button to stop the dose as soon as the product hose is filled to the collection manifold. If you
are sending the flow to the calibration vase, open the valve at the bottom of the vase.
After each calibration you will be required to run a flush to clean the delivery channel. If you are sending the flow to
the calibration vase, watch out for an overflow when doing the flush. It is important to take into account the chemical
incompatibilities when choosing the order of the products to prime. If the delivery channel or vase is not sufficiently cleaned by
the flush, do a water calibration until you are satisfied.
3.O4 Calibration of Products
Now that all the hoses are primed, you can do the product calibrations. Select the Product whose delivery you wish to
calibrate in the calibration screen, and choose the calibration vase as the destination. Check that the valve at the bottom of
the calibration vase is closed. Press and hold the calibration button while sending the dosage to the vase. Remember that the
vase will begin to fill with water, not product, which is correct since the volume of water is the same as the volume of product
being pulled from the collection manifold.
Release the button to stop the dose when there is a representative sample in the vase (use the average of the maximum and
minimum dose for each chemical), check the volume scale on the side of the vase and enter the actual volume pumped on
the PLC touchscreen in milliliters.
3.O5 Calibration of Water
Although you could calibrate water delivery to the calibration vase, calibrating at the washer farthest from the main panel
provides the worst case scenario for pumping against back pressure. Put a bucket or other container at the inlet hose for
the washer, and hold the Calibration button down long enough to get a sizable volume delivered, like half a gallon (2 liters).
Carefully measure the volume of water that was delivered and enter that volume in the Actual field for the calibration in
milliliters.
3.O6 Check the Dosage Calibration with Manual Dose
To verify the flow meter measurements, perform a manual dosage to the calibration vase, with the Flush option set to “No”,
and with the valve at the bottom of the vase closed. Then confirm the volume in the vase is the same as the manual dosage
volume you entered on the PLC display. Since using the manual dose function to check the flow meter measurement must
be done with the vase valve closed and without flush, you will have to open the vase valve and flush the delivery channel as a
separate operation.
3.O7 Adjusting Flush Time for Each Washer Extractor
Use the Manual Dose function (with the Flush Option set to “Yes”) and send a dosage to each washer extractor. Choose a
product with a noticeable color, so you can watch at the inlet of the washer extractor and see if the current flush volume is
enough to take the full product dosage inside the washer. If the water flush volume needs to be adjusted, that is done on the
“Parameters of Washer Extractors” screen.
3.O8 Test the System
Run each washer one by one, and verify that the PLC is receiving all the washer’s signals, and responding with the proper
product delivery, based on the formula selected and the configuration for each wash phase. The number of the formula and
the corresponding phases must be reflected in the “View machines” screen.
3.OO system start-up
