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Table of Contents
Related Manuals for Waterous CAFS-CP-2 Series
Summary of Contents for Waterous CAFS-CP-2 Series
- Page 1 Form Number: F-2937 Issue Date: Jan. 18, 2022 Traditional CAFS—CP-2, CL, CX, HL Series Pumps, and TC20 Series Power Take-Offs Installation, Operation, and Maintenance Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • (651) 450-5000 www.waterousco.com...
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Page 2: Table Of Contents
Table of Contents Determining Hose Routing Safety Determining Cable and Wire Routing Safety Precautions Dimensions—Sump, 8-Inch Long Version Introduction Dimensions—Sump, 10-Inch Version Using this Document Dimensions—Tee Sump Viewing the Document Electronically Dimensions—Oil Cooler, 150-P Printing the Document Dimensions—Separator Filter, 100-P and 120-P Symbols Dimensions—Separator Filter, 150-P and 200-P Dimensions—Air Intake Components;... - Page 3 Operation Operating the System Understanding the Shuttle Valve Operation Operating in Unload Mode Operating in Fixed Mode Operating in Auto Mode Shutting Down the System Maintenance Maintenance Schedule Checking the Sump Oil Level Adding Oil to the Sump Changing the Sump Oil Changing the Air Filter Changing the Separator Filter Changing the Oil Filter...
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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 the equipment. Before Operation • Do not install the equipment if you are not familiar with the tools and skills needed to safely perform the required procedures—proper installation is the... - Page 5 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting NOTICE Hot Surface High Current • High current from welding • Hot surfaces can burn you. or plasma cutting can • Do not touch the surface damage components. during operation—allow • Disconnect all ground wire it to cool after operating.
- Page 6 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting High Pressure Moving Parts • Liquid ejected at high • Rotating parts can cause pressure can cause severe injury or death. serious injury. • Do not enter or reach into • Do not operate beyond the compartment when recommended pressure.
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Page 7: Introduction
Maintenance Troubleshooting 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 have not Viewing the Document Electronically purchased with your system. -
Page 8: System Components
The components that require installation depend on the configuration of your system. Additional components such as wire, bulbs, and connectors are sourced by the installer. Contact Waterous for information about available installation kits. - Page 9 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting System Components Feature Feature Description Description Compressor This creates the compressed air for the system—150-P shown. Sump This separates the air/oil mixture. Piloted balance valve This regulates the pressure between the pneumatic and hydraulic parts of the system. Hose length plate This details the recommended minimum hose length for a given diameter.
- Page 10 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting System Components The CAFSystem™ includes the additional illustrated components. The components are color coded for troubleshooting purposes.
- Page 11 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting System Components Feature Feature Description Description Black tubing This 1/4 inch air brake tube connects various components in the system. Red tubing This 1/4 inch air brake tube connects various components in the system. Yellow tubing This 1/4 inch air brake tube connects various components in the system.
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Page 12: Configurations
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting 100-D, 120-D and 150-D CAFS— 100-P and 120-P CAFS— 100-P and 120-P CAFS— HLK Configurations CPK-2 Configuration CLVK Configuration Assembled at the Factory Assembled at the Factory Assembled at the Factory Shipped Loose Shipped Loose Shipped Loose... -
Page 13: 150-D Cafs-Csc20 Configuration
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting 150-D CAFS— 150-ESD CAFS— 150-ESD CAFS— CSC20 Configuration CXSC20 Configuration TC20 Configuration Assembled at the Factory Assembled at the Factory Assembled at the Factory Shipped Loose Shipped Loose Shipped Loose... -
Page 14: 150-P Cafs-Clvk Configuration
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting 150-P CAFS— 150-P CAFS— 150-P CAFS— CLVK Configuration CXVK Configuration CXVPA Configuration Assembled at the Factory Assembled at the Factory Assembled at the Factory Shipped Loose Shipped Loose Shipped Loose... -
Page 15: 150-T Cafs-Cxvt Configuration
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting 150-T CAFS— 200-D CAFS— 200-P CAFS— CXVT Configuration HL400K Configuration CXVK Configuration Assembled at the Factory Assembled at the Factory Assembled at the Factory Shipped Loose Shipped Loose Shipped Loose... -
Page 16: Operation Overview
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Operation Overview... - Page 17 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Operation Overview Description Description Compressor The compressor portion of the system includes the compressor and the components driving the compressor, such as the power take-off (PTO). Air enters the compressor through the air filter. The air is then entrained, or mixed into the oil, and sent to the sump. Compressed air The compressed air portion of the system includes the sump, separator filter, and supporting hoses.
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Page 18: Compressor Components-150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Compressor Components—150-P... - Page 19 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Compressor—150-P Feature Feature Description Description Air filter assembly This filters the incoming air supply to the compressor. Air inlet trim valve (AITV) This calibrates the auto-sync air balance system. Air inlet assembly This controls the air supply to the compressor.
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Page 20: Air Filtration Components
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Air Filtration Components... - Page 21 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Air Filtration Components Feature Feature Description Description 1 Air filter This filters the incoming air—150-P air filter shown. 2 T-bolt clamp This secures the air filter to the air inlet tube. 3 Air inlet tube This routes fresh air to the compressor.
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Page 22: Oil Sump-Vertical
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Oil Sump—Vertical... - Page 23 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Oil Sump—Vertical Feature Feature Description Description Pressure release valve This limits the amount of pressure contained in the sump to 200 psi. Sump body This is where the air/oil mixture is initially separated. Sight window This displays the oil level in the sump.
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Page 24: Oil Sump-Tee
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Oil Sump—Tee... - Page 25 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Oil Sump—Tee The horizontal oil sump port locations are customizable to meet your application. Feature Feature Description Description Sump body This is where the air/oil mixture is initially separated. Pressure release valve This limits the amount of pressure contained in the sump to 200 psi.
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Page 26: Separator Filter
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Separator Filter... - Page 27 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Separator Filter Feature Feature Description Description Mounting bracket This mounts the separator filter on the apparatus. Scavenge tube check valve This routes the recovered oil from the air/oil mixture. Direction of flow indicator This indicates the direction of flow through the separator filter.
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Page 28: Oil Cooler
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Oil Cooler... - Page 29 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Oil Cooler Feature Feature Description Description Oil outlet This is the outlet for the cooled oil. Note: The oil outlet and oil inlet are reversible to suit the needs of your application. Oil inlet This is the inlet for heated oil.
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Page 30: Sump Vent-Optional
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Sump Vent—Optional... - Page 31 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Sump Vent—Optional Feature Feature Description Description 2-way solenoid valve This actuates to vent the sump. Vent fitting This connects to the separator filter. Mounting hole This secures the assembly to the apparatus. Vent muffler This reduces vent noise.
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Page 32: Balance Valve
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Balance Valve... - Page 33 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Balance Valve Feature Feature Description Description Pressure port This connects to the pressure control circuit. Separator filter output This connects to the separator filter. Direction of flow indicator This indicates the direction the air flows through the balance valve. Balance trim valve This adjusts the balance air circuit.
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Page 34: Auto-Sync Mode Switch
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Auto-Sync Mode Switch... - Page 35 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Auto-Sync Mode Switch Feature Feature Description Description Power wire This connects to apparatus power. Wire harness connector This connects to the wire harness on the auto-sync assembly. Mounting hole This secures the plate to the apparatus. Unload mode This mode operates the compressor at approximately 40 psi (2.8 bar).
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Page 36: Auto-Sync Solenoid Assembly
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Auto-Sync Solenoid Assembly... - Page 37 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Auto-Sync Solenoid Assembly Feature Feature Description Description Wire harness This connects to the auto-sync switch. Pressure gauge output This connects to the optional pressure gauge. Balance valve input This connects to the balance valve. Mounting bracket This mounts the auto-sync on the apparatus.
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Page 38: 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. -
Page 39: Determining Panel And Plate Locations
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Determining Panel and Plate Locations Determining Hose Routing Use the following guidelines to determine a location to mount the control panel Use the following guidelines when routing the hoses: and instruction plate: •... -
Page 40: Dimensions-Sump, 8-Inch Long Version
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Sump, 8-Inch Long Version 4.121in 104.66mm 1.373in 34.88mm 6X 1/2-13UNC-2B... -
Page 41: Dimensions-Sump, 10-Inch Version
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Sump, 10-Inch Version 5.190in 131.83mm 1.940in 49.28mm 6X 1/2-13 UNC-2B... -
Page 42: Dimensions-Tee Sump
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Tee Sump 8.318in 211.26mm 0.438in 11.11mm 4.000in 101.60mm 0.250in 5.000in 6.35mm 127.00mm 13.500in 342.90mm 37.389in 949.67mm... -
Page 43: Dimensions-Oil Cooler, 150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Oil Cooler, 150-P 0.285in [7.25mm] 1.250in [31.75mm] Required for Filter Removal 30.169in [766.29mm] Ø 0.500in [12.70mm] 21.321in [541.54mm]... -
Page 44: Dimensions-Separator Filter, 100-P And 120-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Separator Filter, 100-P and 120-P... -
Page 45: Dimensions-Separator Filter, 150-P And 200-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Separator Filter, 150-P and 200-P 150-P 15.966in [405.53mm] 200-P 16.125in [409.58mm] 4.375in [111.13mm]... -
Page 46: Dimensions-Air Intake Components; 100-P, 150-P, And 200-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Air Intake Components; 100-P, 150-P, and 200-P... -
Page 47: Dimensions-Balance Valve
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Balance Valve... -
Page 48: Dimensions-Auto-Sync Solenoid Assembly
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Auto-Sync Solenoid Assembly... -
Page 49: Dimensions-Optional Sump Vent Assembly
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Optional Sump Vent Assembly 6.506in 165.26mm 0.313in 7.95mm 4.405in 1.750in 111.90mm 44.45mm... -
Page 50: Dimensions-Auto-Sync Switch
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Auto-Sync Switch... -
Page 51: Dimensions-Warning, Instruction, And Serial Plates
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Warning, Instruction, and Serial Plates... -
Page 52: Dimensions-Temperature Gauge
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Dimensions—Temperature Gauge... - Page 53 Notes...
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Page 54: Pneumatic Connections-Overview
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Pneumatic Connections—Overview... - Page 55 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Pneumatic Connections—Overview Feature Feature Description Description Compressed air line This line is a black air brake tube that routes compressed air from the auto-sync solenoid assembly to the pressure gauge. Compressed air line This line is a black air brake tube that routes compressed air from the balance valve to the auto-sync solenoid assembly.
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Page 56: Hose Connections Overview-150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Hose Connections Overview—150-P Use the illustration to plan the hose routing for the apparatus. Contact Waterous for more information about available hose and fitting kits. - Page 57 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Hose Connections Overview—150-P Feature Feature Description Description Oil scavenger return hose This routes oil from the scavenger port on the separator filter to the compressor—1/4 inch hydraulic hose. Oil cooler hose This routes oil from the oil cooler to the compressor—1/2 inch hydraulic hose. Compressed air hose This routes compressed air from the compressor to the sump—1-3/8 inch hydraulic hose.
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Page 58: Fittings Overview-150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Fittings Overview—150-P Use the illustration to plan the hose routing for the apparatus. Contact Waterous for more information about available hose and fitting kits. - Page 59 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Fittings Overview—150-P Feature Feature Description Description Hose fitting This is for a 1/4 inch hose—#4 FJIC. Hose fitting This is for a 1-3/8 inch hose—#24 FJIC. 90° adapter fitting This is a #24 MJIC x #24 FJIC. Hose fitting This is for a 1/2 inch hose—#8 FJIC.
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Page 60: Temperature Gauge And Sender Connections Overview
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Temperature Gauge and Sender Connections Overview... - Page 61 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Temperature Gauge and Sender Connections Overview Feature Feature Description Description Power and ignition The temperature gauge and sender are powered by the apparatus and enabled by the ignition. Warning light This is installed on the operator panel and illuminates when the oil in the sump reaches a predetermined temperature—the light and wiring are installer-supplied.
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Page 62: Installing The Oil Sump
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Oil Sump Use the illustrations and instructions to install the oil sump. Note: Make sure to install the sump so that it is easy to access. You must be able to perform regular maintenance and see into the sight window. -
Page 63: Installing The Oil Cooler
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Oil Cooler Use the illustrations and instructions to install the oil cooler. Note: Make sure to install the oil cooler so that it is easy to access. You must be able to perform regular maintenance and drain the oil cooler to prevent freeze damage. -
Page 64: Installing The Separator Filter
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Separator Filter Use the illustrations and instructions to install the air/oil separator. Note: Make sure to install the separator filter so that it is easy to access. 1 Install the separator filter with the filter toward the bottom. -
Page 65: Installing The Balance Valve
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Balance Valve Use the illustrations and instructions to install the balance valve. Note: Make sure to install the balance valve so that it is easy to access. Installing the balance valve where it is not able to be adjusted will void your warranty. -
Page 66: Installing The Auto-Sync Solenoid Assembly
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Auto-Sync Solenoid Assembly Use the illustrations and instructions to install the auto-sync solenoid assembly. 1 Install the auto-sync solenoid assembly with the mounting bracket toward the bottom. 2 Drill the mounting holes for the auto-sync "Dimensions—... -
Page 67: Mounting The Auto-Sync Switch
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Mounting the Auto-Sync Switch Use the illustration and instructions to mount the auto-sync switch on the apparatus. Note: Make sure to install the auto-sync switch so that it is easy to access. 1 Create the cutout and drill the mounting holes for the auto-sync switch. -
Page 68: Connecting The Auto-Sync System
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Connecting the Auto-Sync System Use the illustration and instructions to connect the auto-sync switch wires and components. 1 Secure the power wire to the appropriate power distribution rail. 2 Connect the ground screw to the frame ground. 3 Connect the auto-sync and solenoid wire harness connectors to the wire harness extension. -
Page 69: Installing The Warning, Instruction, Or Serial Plate
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Warning, Instruction, or Serial Plate Use the illustration and instructions to mount the warning, instruction, and serial plates on the apparatus. Note: Make sure to install the plates near the auto- sync switch. -
Page 70: Installing The Compressed Air Hoses-150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Compressed Air Hoses—150-P Use the illustration and instructions to install the compressed air hoses. 1 Install the fitting (#24 FJIC) onto the compressor and sump. 2 Install the 1-3/8 inch hydraulic hose into the fittings (#24 FJIC). -
Page 71: Installing The Scavenge Oil Hose-150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Scavenge Oil Hose—150-P Use the illustration and instructions to install the scavenge oil hose. 1 Install the fittings (#4 FJIC) onto the air compressor and separator filter. 2 Install the 1/4 inch hydraulic hose into the fittings (#4 FJIC). -
Page 72: Installing The Oil Cooler Hoses-Oil Hoses, 150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Oil Cooler Hoses—Oil Hoses, 150-P Use the illustration and instructions to install the oil hoses for the oil cooler. 1 Install the fittings (#8 FJIC) onto the compressor and oil cooler. 2 Install the 1/2 inch hydraulic hose into the fittings (#8 FJIC). -
Page 73: Installing The Oil Cooler Hoses-Water Lines, 150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Oil Cooler Hoses—Water Lines, 150-P Use the illustrations and instructions to install the water lines for the oil cooler. 1 Install the reducer bushing (1 MNPT x 1/2 FNPT) into the wye fitting. 2 Install the straight fitting (1/2 MNPT x 5/8 AB) into the reducer bushings (1 MNPT x 1/2 FNPT) on the wye fitting and pump discharge port. -
Page 74: Installing The Balance Valve Hoses
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Balance Valve Hoses Use the illustration and instructions to install the balance valve hoses. 1 Install the fitting (1/4 MNPT x 1/4 AB) into a port on the high-pressure side of the pump. 2 Connect the orange air brake hose to the balance valve and a discharge port on the pump. -
Page 75: Installing The Pmc Hoses-150-P
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the PMC Hoses—150-P Use the illustration and instructions to install the PMC hoses. 1 Connect the red air brake hose to the auto-sync solenoid assembly and PMC assembly. 2 Connect the black air brake hose to the separator filter and PMC assembly. -
Page 76: Installing The Sump Vent Assembly
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Sump Vent Assembly Use the illustrations and instructions to install the optional sump vent assembly. In some applications, the sump vent solenoid opens for 10 seconds at engine startup to prevent engine stall. 1 Drill the mounting holes for the mounting "Dimensions—Optional bracket. -
Page 77: Installing The Pressure Gauge
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Pressure Gauge Use the illustrations and instructions to install the pressure gauge. The pressure gauge is required by NFPA standards and locally sourced by the installer. 1 Create the cutout for the pressure gauge. For dimensions, refer to the specifications provided by the manufacturer. -
Page 78: Installing The Temperature Gauge
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Temperature Gauge Use the illustrations and instructions to install the temperature gauge. Note: Locally source the appropriate wire and connectors for the gauge. 1 Create the cutout for the temperature gauge. Refer to: "Dimensions—Temperature Gauge"... -
Page 79: Preparing For Operation
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Preparing for Operation Use the illustrations and instructions to prepare the system for operation. This procedure distributes the oil in the sump to the hoses, oil cooler, and other system components. Before you begin the procedure: •... - Page 80 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Preparing for Operation Use the illustrations and instructions to prepare the system for operation. 3 Toggle the auto-sync switch to the Unload position, then engage the compressor for up to 10 seconds. Note: Do not operate the compressor for more than 10 seconds during this procedure.
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Page 81: Calibrating The System-Unload Mode
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Calibrating the System—Unload Mode Use the illustrations and instructions to calibrate the system for unload 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. -
Page 82: Calibrating The System-Fixed Mode
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Calibrating the System—Fixed Mode Use the illustrations and instructions to calibrate the system for fixed 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. - Page 83 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Calibrating the System—Fixed Mode Use the illustrations and instructions to verify that the system is calibrated for fixed mode. When operating the system: • Always start the system in auto or unload mode. •...
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Page 84: Calibrating The System-Auto Mode
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Calibrating the System—Auto Mode Use the illustrations and instructions to adjust the system in 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. - Page 85 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Calibrating the System—Auto Mode Use the illustrations and instructions to adjust the system in 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.
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Page 86: Operating The System
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Operating the System The system operates in 3 modes. Each mode is engaged with the toggle switch on the auto-sync controller. When operating the system: • Always start the system in auto or unload mode. •... -
Page 87: Understanding The Shuttle Valve Operation
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Understanding the Shuttle Valve Operation The shuttle valve engages as the pressure in the system rises. It prevents air from escaping during CAFS operation. When the system shuts down and pressure is no longer applied to the valve, the shuttle returns to its resting position and bleeds off any remaining air in the system to atmosphere. -
Page 88: Operating In Unload Mode
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Operating in Unload Mode Unload mode operates the compressor in standby. The compressor generates a minimum pressure of 40 psi (2.8 bar) to circulate the compressor oil and cool the system. Note: illustrates the main air pressure route described in the instructions. -
Page 89: Operating In Fixed Mode
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Operating in Fixed Mode Fixed mode sets the air pressure at a fixed point. The fixed point for typical applications is 150 psi (10.3 bar). Note: illustrates the main air pressure route described in the instructions. 1 The compressor builds air pressure in the system. -
Page 90: Operating In Auto Mode
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Operating in Auto Mode Auto mode synchronizes the air pressure with the water pressure. The air pressure rises and falls automatically as you raise and lower the water pressure. Auto mode operates between 50 to 150 psi (3.4 to 10.3 bar). -
Page 91: Shutting Down The System
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Shutting Down the System Use the illustrations and instructions to create a shutdown procedure for your application. 1 Close the air valves. 2 Disengage the foam proportioner, then flow water though the discharge hoses until all bubbles are gone. -
Page 92: Maintenance
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Maintenance Schedule Perform the following procedures at the recommended intervals at a minimum. Environmental conditions affect the maintenance requirements. Inspect the components frequently and create a maintenance schedule suitable to your application and environment. Replace wear components with equivalent components. Use your serial number to gain access to the service parts lists associated with your system through the MyWaterous login at www.waterousco.com. -
Page 93: Checking The Sump Oil Level
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Checking the Sump Oil Level Use the illustration and instructions to check the oil level. Check the compressor oil level daily and replenish the oil accordingly. 1 The oil level is too high when it is higher than halfway up the sight window. -
Page 94: Adding Oil To The Sump
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Adding Oil to the Sump Use the illustrations and instructions to add oil to the sump. Purge the pressure from the system before adding the oil. High Pressure • Liquid ejected at high pressure can cause serious injury. -
Page 95: Changing The Sump Oil
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Changing the Sump Oil Use the illustrations and instructions to change the oil in the sump. Purge the pressure from the system before changing the sump oil. High Pressure • Liquid ejected at high pressure can cause serious injury. -
Page 96: Changing The Air Filter
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Changing the Air Filter Use the illustrations and instructions 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. -
Page 97: Changing The Separator Filter
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Changing the Separator Filter Use the illustrations and instructions to change the separator filter. Space constraints may require you to remove the oil filter tube before changing the filter. Purge the pressure from the system before changing the separator filter. -
Page 98: Changing The Oil Filter
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Changing the Oil Filter Use the illustrations and instructions to change the oil filter. Purge the pressure from the system before changing the oil filter. High Pressure • Liquid ejected at high pressure can cause serious injury. -
Page 99: Cleaning The Wye Strainer
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Cleaning the Wye Strainer Use the illustrations and instructions to clean the wye strainer. Purge the pressure from the system before changing the wye strainer. High Pressure • Liquid ejected at high pressure can cause serious injury. -
Page 100: Performing The Weekly Compressor Maintenance
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Performing the Weekly Compressor Maintenance Use the illustrations and instructions to perform the weekly compressor maintenance. Operating the compressor in fixed mode with the air discharge open lubricates and exercises the system. Note: In humid environments, steam can form and escape during this procedure. -
Page 101: Troubleshooting
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Troubleshooting Guide Symptom Symptom Possible Cause Possible Cause Solution Solution The compressor is working, but no The auto-sync switch is not in the correct • Make sure that the air pressure produced in unload mode is between 25 to 40 psi. air is supplied to the discharges. - Page 102 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Symptom Symptom Possible Cause Possible Cause Solution Solution The air discharge pressure is too The red auto-sync tube has detached or Reattach, repair, or replace the tubing. high. is leaking. The trim valve is out of adjustment—the Adjust the trim valve.
- Page 103 The oil level is low or there is no oil. • Add the appropriate amount of oil—the proper oil level is halfway up the sight window when the apparatus is on level ground. • Check the system and repair the damaged components. Contact Waterous for more information.
- Page 104 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Symptom Symptom Possible Cause Possible Cause Solution Solution The air pressure is appropriate but The foam system has not been calibrated Make sure that the foam system has been calibrated—recalibrate the system. the system produces poor quality or is out of calibration.
- Page 105 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Symptom Symptom Possible Cause Possible Cause Solution Solution The safety pop-off valve is The auto-sync system is out of balance. Adjust the auto-sync system —make sure to not open the compressor trim valve more than 3 turns. opening at a low pressure or A sump fire damaged the pop-off valve.
- Page 106 Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Symptom Symptom Possible Cause Possible Cause Solution Solution The discharge hose is shaking The foam proportioner is on, the setting Refer to foam proportioner instructions for detailed calibration and troubleshooting instructions. (slug flow). is correct, and the tank has concentrate, but it is not providing foam solution.
- Page 107 Waterous Company 125 Hardman Avenue South South Saint Paul, MN 55075 (651) 450-5000 www.waterousco.com...