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Hose Connections Overview

Use the illustration to plan the hose routing for the apparatus. Contact Waterous for more information about available hose and fitting kits.

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Страница 1: ...se Compressed Air System Installation Operation and Maintenance Form Number F 3013 Issue Date May 17 2023 Waterous Company 125 Hardman Avenue South South Saint Paul MN 55075 651 450 5000 www waterousc...

Страница 2: ...ction Plate 48 Mounting the Throttle Ready Panel 49 Connecting the Throttle Ready Panel and Interlock 50 Installing the Air Clutch Hose 51 Installing the Pressure Gauge 52 Installing the Temperature G...

Страница 3: ......

Страница 4: ...y perform the required procedures proper installation is the responsibility of the purchaser Do not operate the equipment when safety guards are removed Do not modify the equipment Regularly check for...

Страница 5: ...l ground wire connections before applying high current Drain the pump after use and before servicing Liquid ejected at high pressure can cause serious injury High Pressure Do not touch the surface dur...

Страница 6: ...bleshooting Maintenance Rotating parts can cause severe injury or death Moving Parts Do not enter or reach into the compartment when equipment is operating Do not operate beyond recommended pressure L...

Страница 7: ...rious system configurations Installation This section describes the installation and initial setup procedures Operation This section describes equipment operation Maintenance This section describes re...

Страница 8: ...ilable in 12 V or 24 V Some components are assembled at the factory while other components are shipped loose and require installation The components that require installation depend on the configurati...

Страница 9: ...f operation 3 Auto sync extension harness This is an extension for the auto sync switch wire harness 4 Hose length plate This details the recommended minimum hose length for a given diameter 5 Compres...

Страница 10: ...on Product Overview Installation Operation Troubleshooting Maintenance System Components The CAFSystem includes the additional illustrated components The components are color coded for troubleshooting...

Страница 11: ...g This 3 8 inch tube connects various components in the system 3 Red tubing This 1 4 inch tube connects various components in the system 4 Orange tubing This 1 4 inch tube connects various components...

Страница 12: ...12 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Operation Overview...

Страница 13: ...air and water pressure in auto mode 3 Cooling The cooling portion of the system includes the oil cooler oil filter supporting hoses fire pump and water source After leaving the sump the oil passes th...

Страница 14: ...14 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Compressor Components 1 2 7 8 14 6 5 3 13 9 16 11 12 4 15 10...

Страница 15: ...and number of air injection points depends on your application 6 Balance valve This regulates the air circuit when the system is in auto mode 7 3 way solenoid valve This controls the air flow to the a...

Страница 16: ...16 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Air Filtration Components 4 5 1 2 3 7 6...

Страница 17: ...the air inlet tube 3 Air inlet tube This routes filtered air to the compressor Note If the air filter is unstable after installation provide additional support at the air inlet tube 4 90 rubber elbow...

Страница 18: ...18 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Pressure Modulation Control PMC Assembly 1 3 2 4 5...

Страница 19: ...ressure switch when the PMC reaches a predetermined pressure 2 Blowdown valve This bleeds off any remaining air in the system when it shuts down 3 Pressure regulator This regulates the air circuit in...

Страница 20: ...20 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Air Oil Separation Components 1 5 4 2 3 6 9 10 11 8 7...

Страница 21: ...air outlet This connects to the PMC 5 Compressed air outlet This connects to the air discharge manifold 6 Oil cooler inlet This connects to the oil cooler 7 Oil cooler outlet This connects to the oil...

Страница 22: ...22 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Oil Filter 3 4 5 2 1...

Страница 23: ...cription Description 1 Mounting bracket This is used to mount the oil filter on the apparatus 2 Direction of flow indicator This indicates the direction of flow through the oil filter 3 Oil inlet This...

Страница 24: ...24 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Oil Cooler 5 3 9 8 4 6 2 7 1 3...

Страница 25: ...hat cools the oil 5 Wye strainer clean out valve This allows you to quickly remove accumulated debris from the wye strainer 6 Direction of flow indicator This indicates the direction of water flowing...

Страница 26: ...26 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Balance Valve 6 5 4 7 1 2 3...

Страница 27: ...t This connects to the black solenoid on the auto sync assembly 3 Direction of flow indicator This indicates the direction the air flows through the balance valve 4 Balance trim valve This calibrates...

Страница 28: ...28 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Auto Sync Mode Switch 1 2 4 5 6 7 3...

Страница 29: ...ompressor at approximately 40 psi 2 8 bar The compressor generates a minimum pressure of 40 psi to circulate the compressor oil and cool the system Always start the compressor in this mode or auto mod...

Страница 30: ...30 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Auto Sync Solenoid Assembly 1 3 4 6 5 2...

Страница 31: ...ntified by the black or yellow tubing that feeds into them Feature Feature Description Description 1 Wire harness This connects to the auto sync switch 2 Pressure gauge adapter This connects to the su...

Страница 32: ...32 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Throttle Ready Panel 4 2 3 1...

Страница 33: ...e Description Description 1 Mounting holes These secure the panel to the apparatus 2 Throttle Ready LED This illuminates when the throttle ready interlock is engaged 3 OK to Pump LED This illuminates...

Страница 34: ...34 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Relay Panel Assembly 6b 4 2 3 5 1 6a...

Страница 35: ...ous system components 3 Relay connector These provide a way to connect the system wiring to the relays 4 Terminal block This provides a way to connect various system components to the relay panel 5 Gr...

Страница 36: ...repare a suitable well lit area and gather all the necessary tools before you begin the installation Make sure that you remove any shipping plugs or caps before installing components Make sure that yo...

Страница 37: ...on and maintenance Install instruction plates near their applicable operator panels Determining Hose Routing Use the following guidelines when routing the hoses Route hoses in a straight line whenever...

Страница 38: ...38 90 Safety Introduction Product Overview Installation Operation Troubleshooting Maintenance Pneumatic Connections Overview 1 2 3 5 9 10 4 6 7 8...

Страница 39: ...nced air line This is a yellow tube that routes balanced air from the balance valve to the auto sync solenoid assembly 5 Regulated air line This is a red tube that routes regulated air from the auto s...

Страница 40: ...view Installation Operation Troubleshooting Maintenance Hose Connections Overview Use the illustration to plan the hose routing for the apparatus Contact Waterous for more information about available...

Страница 41: ...compressor to the oil filter 1 2 inch hydraulic hose 3 Oil cooler hose This routes oil from the compressor to the oil cooler 1 2 inch hydraulic hose 4 Oil cooler hose This routes oil from the oil coo...

Страница 42: ...stallation Operation Troubleshooting Maintenance Fittings Overview Use the illustration to plan the hose routing for the apparatus Contact Waterous for more information about available hose and fittin...

Страница 43: ...ch hose 8 FJIC 4 Reducing bushing This is a 1 MNPT x 1 2 FNPT 5 Straight adapter This is a 6 MSAE x 1 2 MNPT 6 90 elbow adapter This is a 6 MSAE x 1 2 MNPT 7 Swivel hose fitting This is for a 3 8 inch...

Страница 44: ...all the oil cooler drain line Fluid that is susceptible to freezing must be drained from the cooler to prevent damage NOTICE Do not allow fluid in the lines to freeze Remove all freezable fluid from t...

Страница 45: ...Notes...

Страница 46: ...Use the illustration and instructions to mount the auto sync switch on the operator panel Note Make sure to install the auto sync switch so that it is easy to access 1 Create the cutout and drill the...

Страница 47: ...nstructions to connect the auto sync switch wires and components 1 Secure the power wire from the auto sync switch to terminal 4 on the relay panel 2 Secure the ground wire to the grounding screws on...

Страница 48: ...on Plate Use the illustration and instructions to mount the warning and instruction plates on the apparatus Note Make sure to install the plates near the auto sync switch 1 Drill the mounting holes fo...

Страница 49: ...Throttle Ready Panel Use the illustration and instructions to mount the throttle ready panel on the apparatus Note Make sure to install the panel so that the LEDs are easily visible 1 Drill the mounti...

Страница 50: ...nd Interlock 1 2 Use the illustration and instructions to connect the throttle ready panel wires and components 1 Connect the panel connector to the interlock connector 2 Secure one of the interlock c...

Страница 51: ...llation Operation Troubleshooting Maintenance Installing the Air Clutch Hose Use the illustration and instructions to install the air clutch hose 1 Use a portion of the yellow tubing to connect the ve...

Страница 52: ...o install the pressure gauge on the control panel The pressure gauge is required by NFPA standards and must be locally sourced by the installer 1 Create the cutout for the pressure gauge For dimension...

Страница 53: ...roubleshooting Maintenance Installing the Temperature Gauge Use the illustration and instructions to install the temperature gauge on the control panel 1 Create the cutout for the temperature gauge th...

Страница 54: ...on the temperature sender 2 Secure the power wire between the positive terminal on the gauge and terminal 4 on the relay panel 3 Secure the neutral wire between the smaller spade on the temperature s...

Страница 55: ...er Use the illustration and instructions to connect the power source and ignition to the relay panel Note The wire is supplied by the installer 1 Secure the power wire to terminal 1 on the relay panel...

Страница 56: ...necting the Air Clutch Switch Use the illustration and instructions to connect the air clutch switch to the relay panel Note The switch and wire are supplied by the installer 1 Secure the wire to term...

Страница 57: ...ir Clutch Use the illustration and instructions to connect the air clutch solenoid to the relay panel Note The indicator light and wire are supplied by the installer 1 Secure the wire to terminal 7 on...

Страница 58: ...ischarge solenoids to the relay panel Note The indicator light and wire are supplied by the installer 1 Secure the wire to terminal 7 on the relay panel 2 Install a switch between the relay panel and...

Страница 59: ...nd instructions to connect the overheat indicator light and optional audible alarm to the relay panel Note The indicator light audible alarm and wire are supplied by the installer 1 Secure the wire to...

Страница 60: ...removed from the apparatus and the equipment is clear of debris Make sure that all hardware and connections are properly tightened Make sure that the drain valves are closed Make sure to flow water th...

Страница 61: ...o 10 seconds Note Do not operate the compressor for more than 10 seconds during this procedure Doing so will damage the compressor and void your warranty 4 Allow time for the pressure to be completely...

Страница 62: ...er operate the system with the compressor oil temperature above 250 F 121 C 1 Toggle the auto sync switch to the Unload position 2 Close all air discharges before calibration 3 a Locate the AITV then...

Страница 63: ...ter to regulate the compressor oil temperature during operation Never operate the system with the compressor oil temperature above 250 F 121 C 1 Loosen the locknut on the PMC manual adjustment screw 2...

Страница 64: ...r to regulate the compressor oil temperature during operation Never operate the system with the compressor oil temperature above 250 F 121 C 1 Toggle the auto sync switch to the Unload position to mak...

Страница 65: ...auto mode When operating the system Always start the system in auto or unload mode Always circulate enough cool water to regulate the compressor oil temperature during operation Never operate the syst...

Страница 66: ...pressure 4 If the air pressure remains 10 higher than the water pressure and the balance trim valve is fully open turn the AITV 1 2 turn clockwise After the adjustment takes effect compare the air an...

Страница 67: ...hronizes the air pressure with the water pressure The air pressure rises and falls automatically as you raise and lower the static water pressure Auto mode operates between approximately 50 to 150 psi...

Страница 68: ...valve the shuttle returns to its resting position and bleeds off any remaining air in the system to atmosphere Note The white dots illustrate the main air pressure route described in the instructions...

Страница 69: ...ain air pressure route described in the instructions 1 The compressor builds the air pressure in the system to 40 psi 2 8 bar To adjust the set point refer to Calibrating the System Unload Mode on pag...

Страница 70: ...nd interacts with the regulator components 3 Both solenoids are closed which allows the air pressure to operate independently from the water pressure 4 Pressure builds until it reaches the set point w...

Страница 71: ...re surpasses 40 psi 2 8 bar the minimum pressure valve opens allowing air to move into the manifold 3 Inside the balance valve The water side of the balance valve closes the path for air to move to th...

Страница 72: ...nd instructions to create a shutdown procedure for your application 1 Close the air valves if they are open 2 Disengage the foam proportioner then flow water though the discharge hoses to clean them 3...

Страница 73: ...Months 24 Months Comment Comment Check the oil level X X Note that the oil level drops temporarily during system operation Inspect the hoses and fittings X X Service operation X Operate the system in...

Страница 74: ...e amount of oil Refer to Draining the Compressor Oil on page 75 Note If the oil level is too high it is important to determine the cause Check for water entering the compressor from the pump then repa...

Страница 75: ...l Purge all pressure before servicing Liquid ejected at high pressure can cause serious injury High Pressure 1 Place a suitable container under the compressor to collect the drained oil 2 Uncoil the o...

Страница 76: ...from the system before draining the oil Purge all pressure before servicing Liquid ejected at high pressure can cause serious injury High Pressure 1 Place a suitable container under the cooler to coll...

Страница 77: ...c oil Purge all pressure before servicing Liquid ejected at high pressure can cause serious injury High Pressure 1 When all pressure has been purged from the system remove the oil fill cap 2 Add oil t...

Страница 78: ...to change the air filter 1 Locate the T bolt clamp that secures the air filter to the air tube 2 Loosen the T bolt clamp 3 Remove and discard the air filter 4 Position the new air filter over the air...

Страница 79: ...nstructions to change the separator filter Purge the pressure from the system before changing the separator filter Purge all pressure before servicing Liquid ejected at high pressure can cause serious...

Страница 80: ...ustrations and instructions to change the oil filter Purge the pressure from the system before changing the oil filter Purge all pressure before servicing Liquid ejected at high pressure can cause ser...

Страница 81: ...d at high pressure can cause serious injury High Pressure 1 Open the clean out valve and allow the system drain 2 Remove the clean out valve and adapting components Note Replace any worn or deteriorat...

Страница 82: ...eath Moving Parts Do not enter or reach into the compartment when equipment is operating 1 Remove the top half of the belt guard 2 Loosen the screw on the back of the idler plate 3 Turn the adjustment...

Страница 83: ...When performing this procedure Always start the system in auto or unload mode Always circulate enough cool water to regulate the compressor oil temperature during operation Never operate the system w...

Страница 84: ...is open and properly adjusted The system is functional but the pressure gauge is not indicating the correct pressure The gauge is malfunctioning The air line has detached or is leaking The air line is...

Страница 85: ...ool water to the tank or stop operation until the system is no longer overheating The cooler is partially restricted Check the cooler for debris clear any debris hindering the flow and determine where...

Страница 86: ...the compressor is flooded Remove the appropriate amount of oil the proper oil level is halfway up the sight window when the apparatus is on level ground There was a sump fire Check the system and repa...

Страница 87: ...ing in high humidity The system was exposed to cold temperatures without the oil cooler being drained Test the oil cooler for internal leaks from the water side to the oil side replace the cooler The...

Страница 88: ...a lower engine speed The clutch is engaging the system when the compressor has not had adequate bleed down time Allow the air pressure in the compressor to bleed off before engaging the compressor Th...

Страница 89: ...ure that the air pressure produced in auto mode is 50 psi or more and changes with the water pressure Make sure that the pressure produced in fixed mode is between 145 to 150 psi The compressor is pro...

Страница 90: ...Waterous Company 125 Hardman Avenue South South Saint Paul MN 55075 651 450 5000 www waterousco com...

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