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Waterous 150-70 Installation Manual

Apllies to skid model
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Installation Guide
Applies to Waterous "Skid" Model
150-70
200-100
Rev 1
FOR INSTALLATION CENTER USAGE ONLY
Unit Serial Number ______________________
Waterous, Arizona Operations
7612 North 74th Ave.
Glendale, Arizona 85303
623-979-3398
Fax: 623-979-6949
www.waterousco.com
10/4/2010

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Summary of Contents for Waterous 150-70

  • Page 1 Installation Guide Applies to Waterous “Skid” Model 150-70 200-100 Rev 1 FOR INSTALLATION CENTER USAGE ONLY Unit Serial Number ______________________ Waterous, Arizona Operations 7612 North 74th Ave. Glendale, Arizona 85303 623-979-3398 Fax: 623-979-6949 www.waterousco.com 10/4/2010...
  • Page 2 WATEROUS will assign to Buyer, if requested by Buyer. Defects in replacement part(s), component(s) or product(s), not furnished by Waterous, but suggested in the installation guide, are the responsibility of the installer and the manufacturer of said replacement part(s), component(s) or product(s).

  • Page 3: Table Of Contents

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 3 of 38 Table of Contents SECTION 1. MODULE OVERVIEW ......................5 SECTION 2. INSTALLING THE CAF SYSTEM ..................6 Fork Lifting a CAFS .......................... 6 Hold Down Tabs ..........................
  • Page 4 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 4 of 38 Figure(s) Figure 1 12VDC Terminals Negative (left) and Positive (right) ..............7 Figure 8 Typical CAFS Discharge ......................16 Figure 2 Electrical Auto-sync section ......................28 Figure 3 Basic Front Panel.........................

  • Page 5: Module Overview

    PAGE 5 of 38 SECTION 1. MODULE OVERVIEW The Waterous DS series CAFS modules consist of an engine, compressor, fire pump, foam pump and control panel mounted as a modular unit on a steel base. A water tank is included with the unit, on the same base.

  • Page 6: Installing The Caf System

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 6 of 38 SECTION 2. INSTALLING THE CAF SYSTEM Warning: Do not damage the vehicle chassis during installation. Check with the vehicle manufacturer to make sure the planned bolts are installed in acceptable areas.

  • Page 7: Engine Air Supply For Combustion And Cooling

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 7 of 38 C. Engine Air Supply for Combustion and Cooling The units are usually left open at the top and sides. Only fresh air is suitable for combustion and cooling.

  • Page 8: Fuel Supply

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 8 of 38 E. Fuel supply I. Fuel Filtering The engine has an integral fuel filter with a replaceable element to protect the fuel pump.

  • Page 9: Tank Height Offsets

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 9 of 38 • If the lines are not metal, the material must be heat-resistant 212° F (100°C) • Lines runs must be as straight and short as possible between tank and inlets or outlets, with no kinks.
  • Page 10 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 10 of 38 Comments Installation technique If the auxiliary engine will draw fuel from the tank Filler neck with tank ventilation used by the engine that moves the truck, NFPA...

  • Page 11: Initial Powerup

    SECTION 3. INITIAL POWERUP A. Post-Installation, Pre-Power up Safety Check Before you power-up the Waterous system: 1. Remove all tools, shop towels, hose trimmings and other debris from the compartments. 2. Double-check all hydraulic, air and water lines against the schematics, testing to make sure each connection is tight and that the hose is fully inserted into the fitting.

  • Page 12: Initial Compressor System Power Up

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 12 of 38 I. Initial Compressor System Power up Warning: Compressed air can be dangerous. Make sure the pressure is allowed to bleed down to atmospheric pressure before opening any connections or valves.

  • Page 13: Verifying The Auto Sync Air Balancing System

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 13 of 38 SECTION 4. VERIFYING THE AUTO SYNC AIR BALANCING SYSTEM This system seldom needs adjusting. For pre-built CAFS, the Auto Sync system is adjusted at the factory before shipment.

  • Page 14: Fixed Mode Verification

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 14 of 38 4. With the engine at idle, begin water flow through a discharge or tank re-circulation to ensure that the oil cooler has circulating water.

  • Page 15: Optional Programmable Valve Controller

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 15 of 38 SECTION 5. OPTIONAL PROGRAMMABLE VALVE CONTROLLER The new and improved valve controller uses leading edge microchip technology to provide the user with programmable valve positioning that is both accurate and repeatable.

  • Page 16: Suggested Third-Party Components

    These are suggested parts for the common discharge sizes. 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, as shown below.

  • Page 17: Push-On

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 17 of 38 I. Push-On We have found the most cost-effective hose is the push-on type hose. H101 or H201 general-purpose hose has an acceptable working pressure. Gates, Dayco, Parker, Weatherhead and Aeroquip brands will suffice.

  • Page 18: Troubleshooting

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 18 of 38 SECTION 7. TROUBLESHOOTING Engine Make sure that all required fluids are at the correct level, and that the batteries are charged and connected.

  • Page 19: Cafs

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 19 of 38 A. CAFS Observed Probable Cause Suggested Remedy Symptom Lack of air supply to Lack of air pressure clutch (for air-clutch...
  • Page 20 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 20 of 38 Observed Probable Cause Suggested Remedy Symptom Inadequate water flow Ensure adequate water flow through pump. Check Y strainer for through cooler...
  • Page 21 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 21 of 38 Observed Probable Cause Suggested Remedy Symptom High oil level Check oil level, adjust level to half of the sight glass with vehicle parked on...
  • Page 22 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 22 of 38 Observed Probable Cause Suggested Remedy Symptom Engaging in RUN Engage in AUTO/UNLOAD only position Slight air leak from Repair air leak...

  • Page 23: Pump

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 23 of 38 B. Pump Observed Probable Suggested Remedy Symptom Cause Clean and tighten all Intake connections. Make sure intake hoses and gaskets are in good condition.
  • Page 24 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 24 of 38 Observed Probable Suggested Remedy Symptom Cause A worn or damaged priming valve may leak and cause pump to lose prime.
  • Page 25 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 25 of 38 Observed Probable Suggested Remedy Symptom Cause Place transfer valve in VOLUME (parallel) position when pumping more than two thirds rated capacity.
  • Page 26 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 26 of 38 Observed Probable Suggested Remedy Symptom Cause In general, the above causes and remedies for low pump capacity will also apply to low pump pressure.

  • Page 27: Initial Adjustment Of The Auto-Sync Air Balancing System

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 27 of 38 SECTION 8. INITIAL ADJUSTMENT OF THE AUTO-SYNC AIR BALANCING SYSTEM This seldom needs adjusting after the initial setup if the rest of the system is well maintained.
  • Page 28 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 28 of 38 Figure 3 Electrical Auto-sync section 2. Close all air discharges. 3. Locate the Air Inlet Trim Valve (AITV), near the air inlet on the compressor.

  • Page 29: Fixed Mode Initial Setting

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 29 of 38 Piloted 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.

  • Page 30: Auto Mode Initial Setting

    WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 30 of 38 III. AUTO Mode Initial Setting The pressure for the FIXED mode must have been correctly set before you attempt to adjust the AUTO mode.
  • Page 31 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 31 of 38 Figure 4 Basic Front Panel...
  • Page 32 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 32 of 38 Figure 5 Basic CAFS Layout...
  • Page 33 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 33 of 38 Figure 6 Hydraulic Schematic 5in Vertical Sump...
  • Page 34 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 34 of 38 Figure 7 Electrical Schematic Auto-sync...
  • Page 35 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 35 of 38 Figure 8 Air Schematic Electric Auto-sync 90° Inlet...
  • Page 36 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 36 of 38 Figure 9 Tank Placement - Low...
  • Page 37 WATEROUS ARIZONA DOCUMENT TITLE: 150-70 / 200-100 Installation DOC. NO. REV NO. 1 ISSUE DATE: 6/17/2010 PAGE 37 of 38 Figure 10 Tank Placement - High...

  • Page 38: 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;...

This manual is also suitable for:

200-100

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