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Waterous 500-100-P Operation Manual

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Operation Guide
Applies to Waterous Model
500-100-P
500-120-P
Rev 1
Unit Serial Number ______________________
Waterous Arizona Operations
7612 North 74th Ave.
Glendale, Arizona 85303
623-979-3398
Fax: 623-979-6949
www.waterousco.com
12/22/2011

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  • Page 1 Operation Guide Applies to Waterous Model 500-100-P 500-120-P Rev 1 Unit Serial Number ______________________ Waterous Arizona Operations 7612 North 74th Ave. Glendale, Arizona 85303 623-979-3398 Fax: 623-979-6949 www.waterousco.com 12/22/2011...
  • Page 2 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Warnings, Cautions, and Notes Warning A warning alerts you to a procedure, practice or condition that may result in death or long term injury to personnel or destruction of equipment. Caution...

  • Page 3: Table Of Contents

    Figure 4 Clean Strainer ..........................11 Figure 5 Dirty Strainer ..........................11 Figure 6 Basic CAFS Schematic ........................ 24 Figure 7 500-100-P Dimensions ....................... 25 Figure 8 Hydraulic Schematic ........................26 Figure 9 Air Schematic, Electric Auto-sync, 90° inlet ................. 27 Figure 10 Electric Schematic, Auto-sync ....................

  • Page 4: Section 1. Operating Instructions

    Onboard water supply A. Multiple Uses The Waterous compressed air foam unit can be operated in several pumping modes: water only, foam solution without compressed air, compressed air foam, and compressed air only for support operations such as operating air tools, filling rescue air bags, etc. It is possible to pump foam solution from one discharge while pumping compressed air foam from another, or varying foam consistencies (expansion ratios) from different discharges simultaneously.

  • Page 5: Water Pumping Operations

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 I. Water Pumping Operations All unit operations begin with pumping water. These steps must be followed for operations involving pumping water, foam solution, compressed air or compressed air foam. 1. Connect the hose(s) to the desired discharge(s).

  • Page 6: Compressed Air Only Operation

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 2. Move Auto-Sync controls to the AUTO position. Air pressure as shown on the air pressure gauge should rise to within plus or minus 5% of the water discharge pressure. The Auto-Sync system will balance the air and water pressures throughout a range of 40 PSI up to 150 PSI.

  • Page 7: Shut-Down Procedure

     WARNINGS Compressed air can be dangerous. Read and understand the operating instructions for the Waterous compressed air foam unit and individual components prior to operating.  DO NOT use the compressed air foam unit as an air source for SCBA or any breathing air supply.

  • Page 8: Section 2. Compressor

    The air compressor (air end) is mounted to the transmission of a Waterous CLVK single stage pump and driven by a dry Poly Chain. The pump / air end are PTO driven by the engine.

  • Page 9: Section 3. System Service And Maintenance

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 SECTION 3. SYSTEM SERVICE AND MAINTENANCE Excessive heat build-up and oil system contamination are most common causes of compressor system problems and premature wear. With proper operation and maintenance, the compressor system should far outlast the vehicle it is mounted on. Adherence to the following guidelines will prevent potentially costly damage.

  • Page 10: Maintenance Schedule

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 A. Maintenance Schedule Check Oil Change Change Change Level & for Compressor Separator Oil Leaks Filter Cartridge Daily or After Each Use Annually Every 24 Months Refer to the Engine Manual for recommended engine maintenance.

  • Page 11: Wye Strainer For Cooler

    Caution: Waterous is not responsible for damage due to plugged strainers. If the customer's water system contains excessive debris, 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.

  • Page 12: Section 4. Cafs Nozzle / Flow Rate / Hose Combinations

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 SECTION 4. CAFS NOZZLE / FLOW RATE / HOSE COMBINATIONS A. Nozzles Compressed air foam can be discharged through various types and sizes of nozzles. Fog nozzles breakdown the bubble structure of the foam. This results in “wetter” or reduced expansion foam.

  • Page 13: Section 5. Suggested Guidelines For The Production Of Mid-Range Compressed Air Foam

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 SECTION 5. SUGGESTED GUIDELINES FOR THE PRODUCTION OF MID-RANGE COMPRESSED AIR FOAM A. 1” (25 mm) Hose Diameter Jacketed 1 GPM to 1 CFM ½” Tip Solution Flow: 15 GPM (56.78 LPM) Air Flow: 15 CFM (0.42 m...

  • Page 14: 1-3/4" (44 Mm) Hose Diameter

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 2 GPM to 1 CFM 1” Tip Solution Flow: 60-80 GPM (227.12 – 302.82 LPM) Air Flow: 30-40CFM (0.84 – 1.12 m /min) Disch. Pressure: 100-150 PSI (6.804 - 10.206 BAR) (689.5 - 1034.25 KPA) Min/Max Hose Length: 100’...

  • Page 15: Master Stream

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 NOTE: With 1-3/4” hose lengths of 100’-250’ (30.48 – 76.2 meters), up to 90-120 GPM (340.68 – 454.24 LPM) of water and 40-100 CFM (1.12 – 2.8 m /min)of air may be utilized as a highly effective initial attack flow.

  • Page 16: Section 6. Troubleshooting

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 SECTION 6. TROUBLESHOOTING A. CAFS Observed Probable Cause Suggested Remedy Symptom Lack of air supply to Lack of air pressure clutch (for air-clutch Repair air leak or re-establish air supply from compressor...
  • Page 17 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Observed Probable Cause Suggested Remedy Symptom Inadequate water flow Ensure adequate water flow through pump. Check Y strainer for through cooler obstruction, clean and reinstall Drain and flush cooler water tubes On-board tank used for cooling for a prolonged period - water too hot to effectively cool the compressor.
  • Page 18 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Observed Probable Cause Suggested Remedy Symptom High oil level Check oil level, adjust level to half of the sight glass with vehicle parked on (compressor is flooded) a level surface Compressor locked...
  • Page 19 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Observed Probable Cause Suggested Remedy Symptom Engaging in RUN Engage in AUTO/UNLOAD only position Slight air leak from Repair air leak solenoid to clutch High RPM engagement Engage in lower RPM...

  • Page 20: Pump

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 B. Pump Observed Probable Suggested Remedy Symptom Cause Clean and tighten all Intake connections. Make sure intake hoses and gaskets are in good condition. Use the following procedure to locate air leaks: 1.
  • Page 21 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Observed Probable Suggested Remedy Symptom Cause A worn or damaged priming valve may leak and cause pump to lose prime. Defective priming valve Consult primer Instructions for priming valve repair. Improper clearance in...
  • Page 22 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Observed Probable Suggested Remedy Symptom Cause Place transfer valve In VOLUME (parallel) position when pumping more than Transfer valve set two thirds rated capacity. Improperly When shifting transfer valve, make sure it travels all the way Into new (Does not apply to single position.
  • Page 23 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Observed Probable Suggested Remedy Symptom Cause Relief Valve Sticky pilot valve Disassemble and clean. Replace noticeably worn parts. Malfunction A. Pressure not relieved when Plugged tube lines Disconnect lines and Inspect.

  • Page 24: Waterous Arizona Operations 500-100 & 120-P Operations Rev

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Figure 6 Basic CAFS Schematic Page 24 of 30...
  • Page 25 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Figure 7 500-100-P Dimensions Page 25 of 30...
  • Page 26 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Figure 8 Hydraulic Schematic Page 26 of 30...

  • Page 27: Figure 9 Air Schematic, Electric Auto-Sync, 90° Inlet

    Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Figure 9 Air Schematic, Electric Auto-sync, 90° inlet Page 27 of 30...
  • Page 28 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Figure 10 Electric Schematic, Auto-sync Page 28 of 30...
  • Page 29 Waterous Arizona Operations 500-100 & 120-P Operations Rev 1 Figure 11 Compressor Installation Angles Page 29 of 30...

  • Page 30: Section 7. Conditional 5-Year Warranty Policy

    (5) years from the date the product is first placed in service, or five and one-half (5-1/2) years from the date of shipment by WATEROUS, whichever period shall be the first to expire;...

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500-120-p

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