Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Waterous 200-B
Summary of Contents for Waterous 200-B
- Page 1 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...
- Page 2 Waterous 200-B Belt-Driven Installation Guide Rev- 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. A caution alerts you to a procedure or condition that may result in serious...
-
Page 3: Table Of Contents
Waterous 200-B Belt-Driven Installation Guide Rev- Table of Contents SECTION 1. INSTALLATION OVERVIEW................. 5 Installing Waterous Components ..................6 SECTION 2. AIR COMPRESSOR INSTALLATION ..............7 200-B Compressor ......................7 Air Inlet and Filter ....................... 9 SECTION 3. AIR-OIL RESERVOIR (SUMP) INSTALLATION ..........10 Vertical Sump ........................ - Page 4 Rev- Figure 1 200-B Compressor ......................7 Figure 2 200-B Compressor, rear view................... 8 Figure 3 200-B Bottom mounting bolt pattern (center to center) ............ 8 Figure 4 Universal Mounting Bracket ..................... 9 Figure 5 Adjustable Mounting Head ....................9 Figure 6 Vertical sump ........................
-
Page 5: Installation Overview
Waterous 200-B Belt-Driven Installation Guide Rev- SECTION 1. INSTALLATION OVERVIEW Notes: The instructions are for a typical system. A custom order system will have a similar installation procedure. The illustrations shown in this manual may differ slightly from the parts that were shipped. -
Page 6: Installing Waterous Components
Refer to the Basic CAFS, Hydraulic, and Auto-Sync schematics in this manual to see how the Waterous components connect to the vehicle's foam and water distribution systems. Within the guidelines given here, components can be installed wherever there is room for them to be securely mounted. -
Page 7: Air Compressor Installation
Waterous 200-B Belt-Driven Installation Guide Rev- SECTION 2. AIR COMPRESSOR INSTALLATION All 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. -
Page 8: Figure 2 200-B Compressor, Rear View
Figure 2 200-B Compressor, rear view Make a bracket for mounting the air compressor or purchase the universal mounting bracket kit from Waterous. The correct metric mounting bolts (16 mm) are provided with the compressor kit. Bolted to a bracket under the compressor body. -
Page 9: Air Inlet And Filter
200-B Belt-Driven Installation Guide Rev- A "universal mounting bracket" for the 200-B is included from Waterous. The bracket arm is bolted in place, using the vertical extension if needed, and the adjustable mounting head moved left or right to position the compressor. After the position is determined, weld the mounting head to the bracket arm to secure the compressor. -
Page 10: Air-Oil Reservoir (Sump) Installation
The check valve may be ordered from Waterous when ordering the system. The 200-B has two sump styles, the usual vertical sump and the optional "T-shaped" sump. -
Page 11: T-Sump
To Hydraulic Filter Temperature Meter and Drain 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 for the fittings and lines under the sump. -
Page 12: Oil Fill And Sight Glass
Waterous 200-B Belt-Driven Installation Guide Rev- C. Oil Fill and Sight Glass The oil fill and sight glass on the T-sump have 3 possible positions. They may share the same inlet if installed in a wye fitting as shown below, or be installed in separate inlets. -
Page 13: T-Sump Drain
Waterous 200-B Belt-Driven Installation Guide Rev- D. T-Sump Drain The drain and the output to the hydraulic filter share an outlet port. To Hydraulic Filter Drain SECTION 4. OIL TEMPERATURE GAUGE (ALL SUMPS) Mount the gauge on the pump operator's control panel where it will be easy to monitor. -
Page 14: Separator/Filter Installation
Waterous 200-B Belt-Driven Installation Guide Rev- SECTION 5. SEPARATOR/FILTER INSTALLATION The separator filter can be installed anywhere there is room to securely mount it and run the hydraulic and air lines. Install it vertically, with the housing up, the filter element down. -
Page 15: Heat Exchanger Installation
Waterous 200-B Belt-Driven Installation Guide Rev- SECTION 6. HEAT EXCHANGER INSTALLATION Caution: Do not install a shutoff valve in the heat exchanger water supply. This will result in system overheat and failure, and void the manufacturer’s warranty. The oil returning to the compressor is cooled by passing it through a water-cooled heat exchanger, usually called the cooler. -
Page 16: Connecting The Cooler Water Lines And Wye-Strainer
(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 system. The cooler discharge water may be routed to the booster tank fill tower or returned to the inlet side of the pump, as per the end user's preference. -
Page 17: 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 18: Hydraulic Filter Installation
Install with the housing up, the filter element down. Make sure there is enough room so the filter can be removed and replaced. Make sure the direction of oil flow is correct. NOTE: Waterous has phased out in-line thermostats from the hydraulic circuit. Page 18 of 54... -
Page 19: Auto-Sync Control System Installation
Waterous 200-B Belt-Driven Installation Guide Rev- SECTION 8. AUTO-SYNC CONTROL SYSTEM INSTALLATION The Auto-Sync control system will have manual or (optional) electric control valves. A. Manual Valves FIXED/AUTO Side RUN/UNLOAD Side Figure 22 Auto-Sync Manual Valve Assembly Figure 23 Auto-Sync Control Switches... -
Page 20: Electric Valves (Solenoids)
Waterous 200-B Belt-Driven Installation Guide Rev- 6. Attach the label to the pump control panel. 7. Replace the nuts and knobs on the front of the assembly, making sure to align the knob indicators to FIXED and RUN. 8. Make sure the knobs do not bottom out on the valve bodies. This will prevent the system from working properly. -
Page 21: Balance Valve Installation
Note: Waterous will not accept responsibility for the performance of any systems with an inaccessible PBV. Air in from Separator... -
Page 22: Initial Power-Up
Rev- SECTION 10. INITIAL POWER-UP 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 23: Adjusting The Auto-Sync Air Balancing System
Waterous 200-B Belt-Driven Installation Guide Rev- 5. With the system powered up, turn the Auto-Sync to the RUN/FIXED positions (FIXED for electric Auto-Sync). Air pressure should rise to about 110 PSI. 6. Check for leaks by listening for hissing noises at the fittings. -
Page 24: Fixed Mode Adjustment
Waterous 200-B Belt-Driven Installation Guide Rev- 2. Close all air discharges. 3. Locate the Air Inlet Trim Valve, near the air inlet on the compressor. Air Inlet Trim Valve Fixed/Manual Pressure Regulator Figure 30 Compressor adjustment points 4. Turn the valve clockwise until it is completely closed, then open it three full turns. -
Page 25: Auto Mode Adjustment
Waterous 200-B Belt-Driven Installation Guide Rev- 3. The target operating pressure is 145-150 PSI. Monitor the air pressure reading as you adjust the regulator screw. Give the system several seconds to stabilize between adjustments, and make partial turns of the screw to avoid overshooting the target pressure. - Page 26 Waterous 200-B Belt-Driven Installation Guide Rev- Repeat closing the PBTV one full turn until the air pressure is equal to or up to 5% higher than the water pressure. If the air pressure is too high after a full-turn of the PBTV, turn the Air Inlet Trim Valve clockwise to lower the pressure until the air pressure is equal to or up to 5% higher than the water pressure.
-
Page 27: Suggested Third-Party Components
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. The air check valve prevents foam solution from back-flowing into the compressor and contaminating the oil. -
Page 28: Suggested Air Hose
Waterous 200-B Belt-Driven Installation Guide Rev- B. Suggested Air Hose The interior diameter (I.D.) of the hose is the most important factor, and any hose with the correct I.D. and rated to withstand the expected air system pressures (500 PSIG burst pressure) may be used. -
Page 29: Suggested For 1.5" And 2" Discharges
Waterous 200-B Belt-Driven Installation Guide Rev- D. Suggested for 1.5” and 2” discharges: Use ½” air hose 1- Water Check Valve (wafer, flange or ball & cone style, same size as discharge valve) 1 - ½” Quarter Turn Ball Valve... -
Page 30: Suggested Fittings For Auxiliary Air Outlet
4 - #6 JIC x6 Push Loc 2 - #6 JIC x1/2”NPT-M 90 1 - #6 JIC x ¼”NPT-M 1 – Bulkhead fitting, Waterous part # 2330003 Fittings on all hoses should be 37° JIC G. Air distribution manifold: We suggest NPT fittings with the appropriate number and size ports. However, the manifold can be built with air brake tubing if strict attention is paid to the inside diameters: .375”... -
Page 31: Troubleshooting
Waterous 200-B Belt-Driven Installation Guide Rev- SECTION 14. 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 systems) Compressor not... - Page 32 Waterous 200-B Belt-Driven Installation Guide Rev- Observed Probable Cause Suggested Remedy Symptom Ensure adequate water flow through pump. Check Y strainer for Inadequate water flow obstruction, clean and reinstall Drain and flush cooler water through cooler tubes On-board tank used for cooling for a prolonged period - water too hot to effectively cool the compressor.
- Page 33 Waterous 200-B Belt-Driven Installation Guide Rev- Observed Probable Cause Suggested Remedy Symptom High oil level Check oil level, adjust level to half of the sight glass with vehicle (compressor is flooded) parked on a level surface Compressor locked Sump fire...
- Page 34 Waterous 200-B Belt-Driven Installation Guide Rev- 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 Clutch smoking Not allowing compressor...
-
Page 35: Pump
Waterous 200-B Belt-Driven Installation Guide Rev- 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. Connect Intake hose to pump and attach Intake cap to end of hose. - Page 36 Waterous 200-B Belt-Driven Installation Guide Rev- 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 After prolonged service, wear may increase primer clearance and reduce rotary gear or vane efficiency.
- Page 37 Waterous 200-B Belt-Driven Installation Guide Rev- Observed Probable Suggested Remedy Symptom Cause Place transfer valve in VOLUME (parallel) position when pumping more than two thirds rated capacity. Transfer valve set Improperly Insufficient capacity When shifting transfer valve, make sure It travels all the way Into new (Does not apply to single A.
- Page 38 Waterous 200-B Belt-Driven Installation Guide Rev- Observed Probable Suggested Remedy Symptom Cause In general, the above causes and remedies for low pump capacity will also apply to low pump pressure. Pump speed too low Check pump speed with a tachometer.
-
Page 39: Figure 33 Basic Cafs System
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 33 Basic CAFS System Page 39 of 54... -
Page 40: Figure 34 200-B With "T" Sump
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 34 200-B with “T” Sump Page 40 of 54... -
Page 41: Figure 35 200-B With Vertical Sump
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 35 200-B with Vertical Sump Page 41 of 54... -
Page 42: Figure 36 Compressor Dimensions
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 36 Compressor Dimensions Page 42 of 54... -
Page 43: Figure 37 "T" Sump Dimensions
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 37 "T" Sump Dimensions Page 43 of 54... -
Page 44: Figure 38 10" Vertical Reservoir
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 38 10" Vertical Reservoir Page 44 of 54... -
Page 45: Figure 39 Oil Cooler
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 39 Oil Cooler Page 45 of 54... -
Page 46: Figure 40 200-B Oil And Separator
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 40 200-B Oil and Separator Page 46 of 54... -
Page 47: Figure 41 Separator Bracket
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 41 Separator Bracket Page 47 of 54... -
Page 48: Figure 42 Hydraulic Schematic With "T" Sump
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 42 Hydraulic Schematic with "T" Sump Page 48 of 54... -
Page 49: Figure 43 Hydraulic Schematic With Vertical Sump
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 43 Hydraulic Schematic with Vertical Sump Page 49 of 54... -
Page 50: Figure 44 Electrical Schematic For Auto-Sync
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 44 Electrical Schematic for Auto-sync Page 50 of 54... -
Page 51: Figure 45 Air Schematic, Electric Auto-Sync, 90° Inlet
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 45 Air Schematic, Electric Auto-sync, 90° Inlet Page 51 of 54... -
Page 52: Figure 46 Air Schematic, Manual Auto-Sync, Vertical Inlet
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 46 Air Schematic, Manual Auto-sync, Vertical Inlet Page 52 of 54... -
Page 53: Figure 47 Air Schematic, Manual Auto-Sync, 90° Inlet
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 47 Air Schematic, Manual Auto-sync, 90° Inlet Page 53 of 54... -
Page 54: Figure 48 Panel Cutouts, Electrical & Manual Controls
Waterous 200-B Belt-Driven Installation Guide Rev- Figure 48 Panel Cutouts, Electrical & Manual Controls Page 54 of 54...