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Waterous AQUIS ULTRAFLOW Installation And Operation Manual

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Form Number: F-2927
Issue Date: Jun 29, 2021
AQUIS ULTRAFLOW—Control System
Installation and Operation
Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • (651) 450-5000
www.waterousco.com

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  • Page 1 Form Number: F-2927 Issue Date: Jun 29, 2021 AQUIS ULTRAFLOW—Control System Installation and Operation Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • (651) 450-5000 www.waterousco.com...

  • Page 3: Table Of Contents

    Printing the Document Determining Cable and Wire Routing Product Overview Electrical and Cable Connections—Overview Plumbing Layout AQUIS ULTRAFLOW Industrial Foam Proportioner System Wiring the Source-Select Switch Control Box and Components Connecting Pump Discharge-Pressure Sensor Discharge Line Assemblies and Valves Connecting the Node Controllers...

  • Page 4: Safety

    • Read and understand all the notices and safety precautions. • Be aware that these instructions are only guidelines and are not meant to be definitive. Contact Waterous when you have questions about installing, Modification operating, or maintaining the equipment.

  • Page 5: Introduction

    Operation Maintenance Using this Document Use this document to install and operate your Waterous equipment. Understand the following conditions before continuing with the document: Use the guidelines below when viewing this document. • The instructions may refer to options or equipment that you may not have Viewing the Document Electronically purchased with your system.

  • Page 6: Aquis Ultraflow Industrial Foam Proportioner System

    Safety Introduction Product Overview Installation Operation Maintenance AQUIS ULTRAFLOW Industrial Foam Proportioner System...
  • Page 7 AQUIS ULTRAFLOW Industrial Foam Proportioner System The AQUIS ULTRAFLOW industrial foam proportioner system supplies concentrate into a solution-capable discharge line. A Tellurus™ touchscreen display, or human machine interface (HMI), shows system activity, and provides control over the system using a CANbus protocol. Foam concentrate is sourced from an on-board supply tank or an auxiliary source.
  • Page 8 Safety Introduction Product Overview Installation Operation Maintenance AQUIS ULTRAFLOW Industrial Foam Proportioner System Subsystem Subsystem Description Description Concentrate pump These components support, control, and power the concentrate pump. The components in this subsystem include: • Concentrate pump—this circulates the foam concentrate through the system.
  • Page 9 Safety Introduction Product Overview Installation Operation Maintenance AQUIS ULTRAFLOW Industrial Foam Proportioner System Subsystem Subsystem Description Description Low-flow bypass line This returns a portion of the pumped concentrate in the supply line back to the pump inlet when the desired concentrate output requires the pump to operate at an RPM that is lower than possible by the pump.

  • Page 10: Control Box And Components

    Safety Introduction Product Overview Installation Operation Maintenance Control Box and Components The control system monitors and controls the foam proportioning system. It uses information from various sensors, inputs, and uses CANbus protocol to manage the transport of concentrate throughout your application. Refer to the illustration and the table to learn how the control system operates the foam proportioner.

  • Page 11: Discharge Line Assemblies And Valves

    Safety Introduction Product Overview Installation Operation Maintenance Discharge Line Assemblies and Valves Subsystem Subsystem Description Description Control box This connects to various components in the system and contains the programmable logic controller (PLC). Manual override switch This disables the automatic control of the concentrate control valves. Power disconnect relay This power relay enables and disables power to the DLA.

  • Page 12: Control Box

    83818 Safety Introduction Product Overview Installation Operation Maintenance Control Box The control box connects to various components in the system to monitor and control the foam proportioning system. It contains a main PLC, with an option for a secondary backup PLC.
  • Page 13 Safety Introduction Product Overview Installation Operation Maintenance Control Box Feature Feature Description Description Control box This houses control electronics and PLCs. Mounting tab This mounts the box to the apparatus. Cover This is the sealed IP67 rated cover for the box. Cover latch This secures the cover to the box.

  • Page 14: Control Box Connectors

    83818 Safety Introduction Product Overview Installation Operation Maintenance Control Box Connectors...
  • Page 15 Safety Introduction Product Overview Installation Operation Maintenance Control Box Connectors Feature Feature Description Description Tellurus HMI CANbus This communicates the CANbus signal to the Tellurus display. Discharge CANbus This communicates the CANbus signal to the node controllers on each DLA. Remote I/O CANbus This communicates the CANbus signal to an additional node controller for additional options required in your application.

  • Page 16: Concentrate Supply Level Switch

    53474 Safety Introduction Product Overview Installation Operation Maintenance Concentrate Supply Level Switch The switch activates and deactivates as the concentrate level in the tank changes.
  • Page 17 Safety Introduction Product Overview Installation Operation Maintenance Concentrate Supply Level Switch Feature Feature Description Description M12 connector This connects to the sensor cable from the control box and power. Body This threads into the tank—1/4 NPT. Float This determines the concentrate level in the tank.

  • Page 18: Manual Override Switch

    73664 Safety Introduction Product Overview Installation Operation Maintenance Manual Override Switch The manual override switch disables the automatic control of the concentrate control valves.
  • Page 19 Safety Introduction Product Overview Installation Operation Maintenance Manual Override Switch Feature Feature Description Description Connector This connects to the cable from the control box. Switch This switches the override On or Off. Switch LED This illuminates when the manual override is turned on. Mounting hole This mounts the manual override switch to the apparatus.

  • Page 20: Manual Override Relay

    Safety Introduction Product Overview Installation Operation Maintenance Manual Override Relay The power relay works with the optional manual override switch to disable automatic control of the concentrate control valves.
  • Page 21 Safety Introduction Product Overview Installation Operation Maintenance Manual Override Relay Feature Feature Description Description Power input post ( + ) This connects to the bus power. Power output post (–) This connects to the DLA power. Mounting hole This mounts the power relay to the apparatus. Relay connector This connects to the cable from the control box.

  • Page 22: Split Canbus Cable

    V4219 Safety Introduction Product Overview Installation Operation Maintenance Split CANbus Cable Feature Feature Description Description CANbus output This connects to the next node in the chain or the terminating resistor—female plug. CANbus input This connects to the previous node in the chain or the control box discharge CANbus—male socket. Node connector This connects to the node controller—male socket.

  • Page 23: Terminating Resistor

    Safety Introduction Product Overview Installation Operation Maintenance Terminating Resistor Feature Feature Description Description Terminating resistor This connects to the split CANbus cable female socket connector on the last DLA in the system.

  • Page 24: 2.0 Meter Canbus Cable

    V4189 Safety Introduction Product Overview Installation Operation Maintenance 2.0 Meter CANbus Cable 6.56 ft Feature Feature Description Description M12 connector This is a male connector. Cable This is a violet cable jacket. M12 connector This is a female connector. Note: You can connect 2 or more cables together to achieve a desired length.

  • Page 25: 0.5 Meter Canbus Cable

    V4188 Safety Introduction Product Overview Installation Operation Maintenance 0.5 Meter CANbus Cable 19.68 in 500 mm Feature Feature Description Description M12 connector This is a male connector. Cable This is a violet cable jacket. M12 connector This is a female connector. Note: You can connect 2 or more cables together to achieve a desired length.

  • Page 26: 3.0 Meter Sensor Cable

    V4191 Safety Introduction Product Overview Installation Operation Maintenance 3.0 Meter Sensor Cable 9.84 ft Feature Feature Description Description M12 connector This is a male connector. Cable This is a yellow or gray cable jacket. M12 connector This is a female connector. Note: You can connect 2 or more cables together to achieve a desired length.

  • Page 27: 0.5 Meter Sensor Cable

    V4190 Safety Introduction Product Overview Installation Operation Maintenance 0.5 Meter Sensor Cable 19.68 in 500 mm Feature Feature Description Description M12 connector This is a male connector. Cable This is a yellow or gray cable jacket. M12 connector This is a female connector. Note: You can connect 2 or more cables together to achieve a desired length.

  • Page 28: Manual Override Switch Cable Extension

    73666 Safety Introduction Product Overview Installation Operation Maintenance Manual Override Switch Cable Extension 11.81 in 300 mm Feature Feature Description Description M12 connector This connects to the manual override switch connector on the control box, or an extension cable connected to the control box.

  • Page 29: Manual Override Relay Cable

    73667 Safety Introduction Product Overview Installation Operation Maintenance Manual Override Relay Cable 11.81 in 300 mm Feature Feature Description Description M12 connector This connects to the manual override relay connector on the control box, or an extension cable connected to the control box.

  • Page 30: Concentrate Pump Speed Sensor Cable

    73668 Safety Introduction Product Overview Installation Operation Maintenance Concentrate Pump Speed Sensor Cable 11.81 in 300 mm Feature Feature Description Description M12 connector This connects to the concentrate pump connector on the control box, or an extension cable connected to the control box.

  • Page 31: Concentrate Pump Speed Sensor Cable-Schematic

    Safety Introduction Product Overview Installation Operation Maintenance Concentrate Pump Speed Sensor Cable—Schematic Brown Brown Brown Brown White White White White Blue Blue Blue Blue Black Black Black Black Gray Gray Gray Gray M12 Connector M12 Connector Deutsch Connector Deutsch Connector 1 Vcc, +24 V A Signal 2 Signal...

  • Page 32: Hydraulic Pump Swashplate Control Cable

    73669 Safety Introduction Product Overview Installation Operation Maintenance Hydraulic Pump Swashplate Control Cable 11.81 in 300 mm Feature Feature Description Description M12 connector This connects to the hydraulic pump connector on the control box, or an extension cable connected to the control box. Cable This is a yellow cable jacket.

  • Page 33: Hydraulic Pump Swashplate Control Cable-Schematic

    Safety Introduction Product Overview Installation Operation Maintenance Hydraulic Pump Swashplate Control Cable—Schematic Brown Brown White White Blue Blue Black Black Gray Gray M12 Connector M12 Connector Deutsch Connector Deutsch Connector 1 PWM out—AB PWM out—AB 2 PWM out—CD PWM out—CD 3 PWM return—AB PWM return—AB 4 PWM return—CD...

  • Page 34: Supply Tank Level Cable-Installer Supplied

    Safety Introduction Product Overview Installation Operation Maintenance Supply Tank Level Cable—Installer Supplied Feature Feature Description Description M12 connector This connects to the tank level connector on the control box, or an extension cable connected to the control box. Tank level sensor connector This connects to the installer supplied tank level system.

  • Page 35: Supply Tank Level Cable Schematic -Installer Supplied

    Safety Introduction Product Overview Installation Operation Maintenance Supply Tank Level Cable Schematic —Installer Supplied Brown Brown White White Installer Supplied Tank Level Output Blue Blue 4–20 mA Black Black Gray Gray M12 Connector M12 Connector 1 Vcc, +24 V 2 Reserved 3 Signal—4–20 mA 4 Reserved 5 Shield...

  • Page 36: Installation

    This equipment is intended to be installed by a person or persons with the basic This equipment is intended to operate as designed. Do not remove, modify, or knowledge of installing similar equipment. Contact Waterous with questions change the components in the system. Doing so will void the warranty. Contact about installing the equipment.

  • Page 37: Determining The Control Box Location And Orientation

    Safety Introduction Product Overview Installation Operation Determining the Control Box Location and Orientation • Never mount the control box with the connectors facing upward. • Consider accessibility during operation and maintenance. • Consider the cable and hose routing. • Consider the space required to remove the cover and access the box interior. Determining Cable and Wire Routing Use the Wiring Best Practices document, available at www.waterousco.com, as a guide to select and route wiring for your application.

  • Page 38: Electrical And Cable Connections-Overview

    Safety Introduction Product Overview Installation Operation Electrical and Cable Connections—Overview...
  • Page 39 Safety Introduction Product Overview Installation Operation Electrical and Cable Connections—Overview Feature Feature Description Description Apparatus power This supplies power to the system—installer supplied. Frame ground This connects the negative (–) terminal to the apparatus frame—installer supplied. Negative terminal wire This connects to, or through terminal blocks, to the negative (–) terminal on the apparatus battery—installer supplied.

  • Page 40: Plumbing Layout

    Safety Introduction Product Overview Installation Operation Plumbing Layout Use the illustration as a guide to lay out the plumbing connections in your application.
  • Page 41 Safety Introduction Product Overview Installation Operation Plumbing Layout Description Description Concentrate supply line—this transports concentrate around the system. Concentrate supply refill line—this allows you to fill the on-board tank from an auxiliary source. Priming line—this evacuates air from the concentrate pump inlet as the system primes before operation. Priming bypass line—this prevents contaminating the concentrate during testing and training.

  • Page 42: Wiring The Source-Select Switch

    Safety Introduction Product Overview Installation Operation Wiring the Source-Select Switch Use the illustrations and instructions to wire the M12 source select plug. It is the responsibility of the installer to incorporate a method for the system to determine the concentrate source—an on-board tank or an auxiliary supply.

  • Page 43: Connecting Pump Discharge-Pressure Sensor

    I-2253 L-1222-3 Safety Introduction Product Overview Installation Operation Connecting Pump Discharge-Pressure Sensor Use the illustration and instructions to connect the pump discharge-pressure sensor. 1 Use a sensor cable to connect the pump pressure sensor to the control box—the pump pressure connection. Note: Connect 2 or more cables together to achieve a desired length.

  • Page 44: Connecting The Node Controllers

    Safety Introduction Product Overview Installation Operation Connecting the Node Controllers Use the illustration and instructions to use the CANbus cables to connect the control box to the node controllers. 1 Connect the split CANbus cable to the CANbus connector on the node controller. 2 Connect the male end on the split CANbus cable to an upstream node controller, or to the control box—the discharge CANbus connection.

  • Page 45: Connecting The Tellurus Display

    Safety Introduction Product Overview Installation Operation Connecting the Tellurus Display Use the illustration and instructions to connect the Tellurus display. 1 Connect the compatible connector on the Tellurus HMI cable assembly to the Tellurus display connector. 2 Connect the compatible connector on the Tellurus HMI cable assembly to the display extension cable connector.

  • Page 46: Connecting The Concentrate Supply Level Sensors

    I-2257 L-1222-7 Safety Introduction Product Overview Installation Operation Connecting the Concentrate Supply Level Sensors Use the illustration and instructions to connect the concentrate supply level sensors. 1 Use a sensor cable to connect the tank high switch to the control box—concentrate tank high connection.

  • Page 47: Connecting The Concentrate Pump, Pressure Sensor, And Source Select Valve

    I-2257 L-1222-7 Safety Introduction Product Overview Installation Operation Connecting the Concentrate Pump, Pressure Sensor, and Source Select Valve Use the illustration and instructions to connect the concentrate pump speed sensor, concentrate line pressure sensor, and source select valve. 1 Use a sensor cable to connect the concentrate pump speed sensor to the control box—the pump speed connection.

  • Page 48: Connecting The Hydraulic Fluid Reservoir Sensors, Suction Strainer, And Hydraulic Pump

    I-2258 L-1222-8 Safety Introduction Product Overview Installation Operation Connecting the Hydraulic Fluid Reservoir Sensors, Suction Strainer, and Hydraulic Pump Use the illustration and instructions to connect the hydraulic reservoir sensors, reservoir sensor, and the hydraulic pump to the control box. 1 Use a sensor cable to connect the temperature sensor to the control box—the ATF temperature connection.

  • Page 49: Installing The Manual Override

    Safety Introduction Product Overview Installation Operation Installing the Manual Override Use the illustration and instructions to connect the manual-override switch and power relay. 1 To install the manual-override switch, do the following: • Install the manual-override switch into the operator panel. •...

  • Page 50: Connecting The Manual Override

    Safety Introduction Product Overview Installation Operation Connecting the Manual Override Use the illustration and instructions to connect the optional manual-override switch and power relay. 1 Use the manual-override cable to connect it to the control box—the manual override switch connection. Note: Use an additional sensor cable if necessary.
  • Page 51 Notes...

  • Page 52: Connecting To A Node Controller

    Safety Introduction Product Overview Installation Operation Connecting to a Node Controller Use the illustration and table to understand the various cable connections between a node controller and the control box.
  • Page 53 Safety Introduction Product Overview Installation Operation Connecting to a Node Controller Feature Feature Description Description Control box This connects to various components in the system and contains the programmable logic controllers (PLC). CANbus extension This connects the node controllers to one another and the control box. Node controller This connects to the concentrate control valve, flowmeters, and additional discharge line assemblies (DLA).

  • Page 54: Connecting The 1-Inch Dla

    I-2251 L-1222-1 Safety Introduction Product Overview Installation Operation Connecting the 1-Inch DLA Use the illustration and instructions to connect the 1-inch DLA to the control box, and the paddlewheel flowmeter to the node controller. 1 Connect the split CANbus cable to the CANbus connector on the node controller.

  • Page 55: Connecting The 2-Inch Dla And Paddlewheel Flowmeter

    I-2252 L-1222-2 Safety Introduction Product Overview Installation Operation Connecting the 2-Inch DLA and Paddlewheel Flowmeter Use the illustration and instructions to connect the 2-inch DLA and the paddlewheel flowmeter to the control box. 1 Connect the split CANbus cable to the CANbus connector on the node controller.

  • Page 56: Connecting The Priming Valve

    I-2254 L-1222-4 Safety Introduction Product Overview Installation Operation Connecting the Priming Valve Use the illustration and instructions to connect the priming valve to the control box. 1 Connect the split CANbus cable to the CANbus connector on the priming valve motor cable. 2 Connect the male end on the split CANbus cable to an upstream node controller, or to the control box—the discharge CANbus connection.

  • Page 57: Connecting The Low-Flow Bypass Line

    I-2254 L-1222-4 Safety Introduction Product Overview Installation Operation Connecting the Low-Flow Bypass Line Use the illustration and instructions to install the low-flow bypass line. To connect to the apparatus plumbing, refer to: "Plumbing Layout" on page 1 Connect the split CANbus cable to the CANbus connector on the node controller.

  • Page 58: Connecting The Supply Tank Fill Line

    I-2254 L-1222-4 Safety Introduction Product Overview Installation Operation Connecting the Supply Tank Fill Line Use the illustration and instructions to install the supply tank fill line. To connect to the apparatus plumbing, refer to: "Plumbing Layout" on page 1 Connect the split CANbus cable to the CANbus connector on the node controller.

  • Page 59: Operation

    Safety Introduction Product Overview Installation Operation Maintenance Enabling the Manual Override Use the illustrations and instructions to activate the manual override. 1 Use the switch to activate the manual override. 2 Slowly move the valve actuator to the desired position. Note: After manually repositioning the valve actuator, you may need to recalibrate the valve actuator.

  • Page 60: Maintenance

    Safety Introduction Product Overview Installation Operation Maintenance Maintenance Schedule No scheduled maintenance is required for the control system. However, it is recommended that you periodically inspect the system to reveal excessive debris buildup or worn components. Consider environmental conditions, hours of operation, and other factors specific to your application to develop a suitable inspection schedule.
  • Page 61 Notes...
  • Page 62 Waterous Company 125 Hardman Avenue South South Saint Paul, MN 55075 (651) 450-5000 www.waterousco.com...

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