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Form Number: F-3013 Issue Date: May 17, 2023 Eclipse™ Compressed Air System Installation, Operation, and Maintenance Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • (651) 450-5000 www.waterousco.com...
Table of Contents Mounting the Throttle Ready Panel Safety Connecting the Throttle Ready Panel and Interlock Safety Precautions Installing the Air Clutch Hose Introduction Installing the Pressure Gauge Using this Document Installing the Temperature Gauge Viewing the Document Electronically Connecting the Temperature Gauge Printing the Document Connecting to the Relay Panel Additional Documentation...
• 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...
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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.
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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.
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.
System Components The Eclipse™ CAFSystem includes the illustrated components. The system is available in 12 V or 24 V. Some components are assembled at the factory, while other components are shipped loose and require installation. The components that require installation depend on the configuration of your system. Additional...
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting System Components Feature Feature Description Description Compressor This creates the compressed air for the system. Auto-sync switch This selects the mode of operation. Auto-sync extension harness This is an extension for the auto-sync switch wire harness. Hose length plate This details the recommended minimum hose length for a given diameter.
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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.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting System Components Feature Feature Description Description Black tubing This 1/4 inch tube connects various components in the system. Black tubing This 3/8 inch tube connects various components in the system. Red tubing This 1/4 inch tube connects various components in the system.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Operation Overview Feature Feature Description Description Compressor The compressor portion of the system includes the compressor and the components driving the compressor, such as the transmission. Air enters the compressor through the air filter. The air is then entrained, or mixed into the oil, and moved to the compressor's internal sump.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Compressor Components Feature Feature Description Description Air filter assembly This filters the incoming air supply to the compressor. Air/oil separation components This includes the separator filter, air/oil diverter, and other components connected to the air/oil diverter that filter the air/oil and move it through the system.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Air Filtration Components Feature Feature Description Description 1 Air filter This filters the incoming air. 2 T-bolt clamp This secures the air filter to the air inlet tube. 3 Air inlet tube This routes filtered air to the compressor.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Pressure Modulation Control (PMC) Assembly Feature Feature Description Description 1 Pressure sensor This activates the pressure switch when the PMC reaches a predetermined pressure. 2 Blowdown valve This bleeds off any remaining air in the system when it shuts down. 3 Pressure regulator This regulates the air circuit in fixed mode and limits the system's maximum pressure in auto mode.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Air/Oil Separation Components Feature Feature Description Description 1 Separator filter This removes the remaining oil from the air/oil mixture during the final stage of air/oil separation. 2 Oil thermostat This regulates the oil temperature by diverting the oil to the cooler when it reaches a predetermined temperature. 3 Oil return sight plug This displays the oil level in the oil return.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Oil Filter Feature Feature Description Description Mounting bracket This is used to mount the oil filter on the apparatus. Direction of flow indicator This indicates the direction of flow through the oil filter. Oil inlet This is the inlet for the unfiltered oil.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Oil Cooler Feature Feature Description Description Oil inlet This is the inlet for the heated oil. Oil outlet This is the outlet for the cooled oil. Mounting bracket These are used to mount the oil cooler on the apparatus. Water inlet This is the inlet for the water that cools the oil.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Balance Valve Feature Feature Description Description Pressure port This connects to the pressure control circuit. Auto-sync output This connects to the black solenoid on the auto-sync assembly. Direction of flow indicator This indicates the direction the air flows through the balance valve. Balance trim valve This calibrates the air in auto mode.
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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 holes These secure the plate to the apparatus. Unload mode This mode operates the compressor at approximately 40 psi (2.8 bar).
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Auto-Sync Solenoid Assembly Note: The solenoids are color-coded for ease of identification in the illustrations. On the compressor assembly, the solenoids can be identified by the black or yellow tubing that feeds into them. Feature Feature Description...
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Throttle Ready Panel Feature Feature Description Description Mounting holes These secure the panel to the apparatus. Throttle Ready LED This illuminates when the throttle ready interlock is engaged. OK to Pump LED This illuminates when the OK to pump interlock is engaged.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Relay Panel Assembly Feature Feature Description Description Terminal strip This provides a way to connect various system components to the relay panel. Relay These are switches that control various system components. Relay connector These provide a way to connect the system wiring to the relays.
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.
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: •...
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Pneumatic Connections Overview Feature Feature Description Description Compressed air line This is a black tube that routes compressed air from the auto-sync solenoid assembly to the pressure gauge. Compressed air line This is a black tube that routes compressed air from the PMC to the balance valve. Compressed air line This is a black tube that routes compressed air from the balance valve to the auto-sync solenoid assembly.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Hose Connections Overview Use the illustration to plan the hose routing for the apparatus. Contact Waterous for more information about available hose and fitting kits.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Hose Connections Overview Note: The oil cooler and the oil filter cannot be connected in series. Feature Feature Description Description Oil filter hose This routes oil from the oil filter to the compressor—1/2 inch hydraulic hose. Oil filter hose This routes oil from the compressor to the oil filter—1/2 inch hydraulic hose.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Fittings Overview Use the illustration to plan the hose routing for the apparatus. Contact Waterous for more information about available hose and fitting kits.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Fittings Overview Feature Feature Description Description Hose fitting This is for a 1/2 inch hose—#8 FJIC. 45° hose fitting This is for a 1/2 inch hose—#8 FJIC. 90° hose fitting This is for a 1/2 inch hose—#8 FJIC. Reducing bushing This is a 1 MNPT x 1/2 FNPT.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Oil Cooler Drain Line Use the illustration and instructions to install the oil cooler drain line. Fluid that is susceptible to freezing must be drained from the cooler to prevent damage. NOTICE Freeze Damage •...
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 operator panel. 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.
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 from the auto-sync switch to terminal 4 on the relay panel. 2 Secure the ground wire to the grounding screws on the auto-sync mounting bracket and the relay panel.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Mounting the Warning or Instruction Plate Use the illustration and instructions to mount the warning and instruction plates on the apparatus. Note: Make sure to install the plates near the auto- sync switch. 1 Drill the mounting holes for the warning and instruction plates on the apparatus.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Mounting the Throttle Ready Panel Use the illustration and instructions to mount the throttle ready panel on the apparatus. Note: Make sure to install the panel so that the LEDs are easily visible. 1 Drill the mounting holes for the throttle ready panel.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Connecting the Throttle Ready Panel and Interlock Use the illustration and instructions to connect the throttle ready panel wires and components. 1 Connect the panel connector to the interlock connector. 2 Secure one of the interlock connector wires to terminal 2 on the relay panel.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Air Clutch Hose Use the illustration and instructions to install the air clutch hose. 1 Use a portion of the yellow tubing to connect the vehicle air supply and the 3-way solenoid valve.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Pressure Gauge Use the illustrations and instructions to install the pressure gauge on the control panel. The pressure gauge is required by NFPA standards and must be locally sourced by the installer. 1 Create the cutout for the pressure gauge.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Installing the Temperature Gauge Use the illustration and instructions to install the temperature gauge on the control panel. 1 Create the cutout for the temperature gauge, then use the provided hardware to secure the gauge to the apparatus.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Connecting the Temperature Gauge Use the illustration and instructions to connect the temperature gauge wires and components. Note: The wire is supplied by the installer. 1 Secure the neutral wire between the signal terminal on the gauge and the larger spade on the temperature sender.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Connecting to the Relay Panel Connecting to Power Use the illustration and instructions to connect the power source and ignition to the relay panel. Note: The wire is supplied by the installer. 1 Secure the power wire to terminal 1 on the relay panel.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Connecting to the Relay Panel Connecting the Air Clutch Switch Use the illustration and instructions to connect the air clutch switch to the relay panel. Note: The switch and wire are supplied by the installer.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Connecting to the Relay Panel Connecting the Air Clutch Use the illustration and instructions to connect the air clutch solenoid to the relay panel. Note: The indicator light and wire are supplied by the installer.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Connecting to the Relay Panel Connecting the Air Discharges Use the illustration and instructions to connect the air discharge solenoids to the relay panel. Note: The indicator light and wire are supplied by the installer.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Connecting to the Relay Panel Connecting the Overheat Light and Audible Alarm Use the illustration and instructions to connect the overheat indicator light and optional audible alarm to the relay panel. Note: The indicator light, audible alarm, and wire are supplied by the installer.
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 compressor to the hoses, oil cooler, and other system components. Before you begin the procedure: •...
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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.
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.
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.
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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. •...
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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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.
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. •...
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Understanding the Shuttle Valve Operation The shuttle valve engages as the air pressure in the system rises. It prevents air from escaping during CAFS operation. When the system shuts down and the air pressure leaves the valve, the shuttle returns to its resting position and bleeds off any remaining air in the system to atmosphere.
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: The white dots illustrate the main air pressure route described in the instructions.
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: The white dots illustrate the main air pressure route described in the instructions.
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).
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 if they are open. 2 Disengage the foam proportioner, then flow water though the discharge hoses to clean them.
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.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Checking the Compressor Oil Level Use the illustrations and instructions to check the compressor oil level. Check the oil level daily when the system is not in use and replenish the oil as needed. 1 The oil level is too high when it is higher than halfway up the sight glass.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Draining the Compressor Oil Use the illustration and instructions to drain the oil in the compressor. Purge the pressure from the system before draining the oil. High Pressure • Liquid ejected at high pressure can cause serious injury.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Draining the Oil Cooler Use the illustration and instructions to drain the oil in the cooler. Purge the pressure from the system before draining the oil. High Pressure • Liquid ejected at high pressure can cause serious injury.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Adding the Compressor Oil Use the illustrations and instructions to add oil to the sump. Purge the pressure from the system before adding the oil. Use ISO 68 low-foaming or anti-foam hydraulic oil. High Pressure •...
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.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Changing the Separator Filter Use the illustrations and instructions to change the separator filter. Purge the pressure from the system before changing the separator filter. High Pressure • Liquid ejected at high pressure can cause serious injury.
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.
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.
Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Adjusting the Belt Tension Use the illustrations and instructions to adjust the air clutch belt tension. Adjustment is only needed if the belt is loosened or removed to service other system components. Note: Certain components have been removed from the illustrations to provide a clear view of the equipment.
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.
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.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Symptom Symptom Possible Cause Possible Cause Solution Solution The system is overheating (water Water is not flowing through the cooler. • Make sure that water is flowing through the pump. cooling). • Make sure that the lines are not kinked or obstructed—clear any obstructions. The system is overheating with The compressor oil level is too low.
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• 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. 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.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Symptom Symptom Possible Cause Possible Cause Solution Solution The foam pump is disabled and Foam concentrate was poured into the Flush the tank and pump with clean water, then refill. there is foam in the water system. on-board water tank.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Symptom Symptom Possible Cause Possible Cause Solution Solution The bleed-down time seems too The bleed-down time varies between If the auto-sync system is working properly and the compressor output is within spec, the bleed-down time is normal. long during system shutdown.
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Safety Introduction Product Overview Installation Operation Maintenance Troubleshooting Symptom Symptom Possible Cause Possible Cause Solution Solution The compressor is producing no The clutch is not engaging. • Make sure that the clutch is operating properly—check air clutch systems for leaks. air pressure.
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Waterous Company 125 Hardman Avenue South South Saint Paul, MN 55075 (651) 450-5000 www.waterousco.com...
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