Related Manuals for Waterous AQUIS ULTRAFLOW 500
Summary of Contents for Waterous AQUIS ULTRAFLOW 500
- Page 1 Form Number: F-3043 Issue Date: Jul 17, 2024 AQUIS™ ULTRAFLOW 500 Controls—Control Box 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 3: Table Of Contents
Table of Contents Connecting Power to the Control Box Safety Installing the Optional Manual Override Safety Precautions Wiring the Source-Select Switch Introduction Connecting Pump Discharge Pressure Sensor Using this Document Connecting the Node Controllers Viewing the Document Electronically Connecting the Control Panel Printing the Document Connecting the Concentrate Supply Level Sensors Additional Documentation... -
Page 4: Safety
• Read and understand all the notices and safety precautions. operating or overhauling the equipment. • Do not operate the equipment when safety guards are removed. • Contact Waterous when you have questions about operating, maintaining, or • Do not modify the equipment. overhauling 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 Overview Installation Operation Maintenance Aquis UltraFlow Industrial Foam Proportioner System Note: Make sure that the installer-supplied UltraFlow plumbing cannot trap fluid and allows fluid to be drained from the system when required. - Page 7 Safety Introduction Overview Installation Operation Maintenance Aquis UltraFlow Industrial Foam Proportioner System The Aquis UltraFlow industrial foam proportioner system supplies concentrate into a solution-capable discharge line. A Tellurus™ control panel, or human machine interface (HMI), shows system activity and provides control of the system using a CANbus protocol. Foam concentrate is sourced from an on-board supply tank or an auxiliary source.
- Page 8 Safety Introduction 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 Overview Installation Operation Maintenance Aquis UltraFlow Industrial Foam Proportioner System Subsystem Subsystem Description Description Concentrate supply refill line This allows you to fill the on-board tank from an external source. The components in this subsystem include: • Node controller—this connects to the fill valve and flowmeters. •...
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Page 10: Control Box And Components
Safety Introduction Overview Installation Operation Maintenance Control Box and Components The control box monitors and controls the foam proportioner system. It takes information from various sensors and inputs and uses CAN to transport concentrate throughout your application. -
Page 11: Discharge Line Assemblies And Valves
Safety Introduction 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 PLC. Manual override panel This disables the automatic control of the concentrate control valves. Power relay panel This power relay enables and disables power to the DLA. -
Page 12: Control Box
Safety Introduction Overview Installation Operation Maintenance Control Box The control box connects to various components to monitor and control the foam proportioner system. It contains a main PLC with an option for a secondary backup PLC. - Page 13 Safety Introduction Overview Installation Operation Maintenance Control Box Feature Feature Description Description Control box This houses control electronics and PLCs. Mounting tabs These mount the box on the apparatus. Cover This is the sealed IP67 rated cover for the box. Cover latches These secure the cover to the box.
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Page 14: Control Box Connectors
Safety Introduction Overview Installation Operation Maintenance Control Box Connectors... - Page 15 Safety Introduction Overview Installation Operation Maintenance Control Box Connectors Feature Feature Description Description Tellurus HMI CANbus This communicates the CAN signal to the control panel. Discharge CANbus This communicates the CAN signal to the node controllers on each DLA. Remote I/O CANbus This communicates the CAN signal to an additional node controller for options required in your application.
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Page 16: Concentrate Level Switch
Safety Introduction Overview Installation Operation Maintenance Concentrate Level Switch The switch activates and deactivates as the foam concentrate level in the tank changes. - Page 17 Safety Introduction Overview Installation Operation Maintenance Concentrate 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 foam concentrate level in the tank.
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Page 18: Manual Override Panel
Safety Introduction Overview Installation Operation Maintenance Manual Override Panel The optional manual override panel disables the automatic control of the concentrate control valves. - Page 19 Safety Introduction Overview Installation Operation Maintenance Manual Override Panel Feature Feature Description Description M12 connector This connects to the control box. Switch This switches the manual override On or Off. Switch LED This illuminates when the manual override is turned on. Mounting holes These mount the manual override panel on the apparatus.
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Page 20: Power Relay Panel
Safety Introduction Overview Installation Operation Maintenance Power Relay Panel The optional power relay works with the manual override panel to disable automatic control of the concentrate control valves. - Page 21 Safety Introduction Overview Installation Operation Maintenance Power Relay Panel Feature Feature Description Description Power input post ( + ) This connects to the bus power. Power output post (–) This connects to the DLA power. Mounting holes These mount the power relay panel on the apparatus. Connector This connects to the cable from the control box.
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Page 22: Terminating Resistor
Safety Introduction Overview Installation Operation Maintenance Terminating Resistor Feature Feature Description Description Terminating resistor This connects to the node connector on the CAN cable splitter on the last DLA in the system. -
Page 23: Can Cable Splitter
Safety Introduction Overview Installation Operation Maintenance CAN Cable Splitter The CAN cable splitter communicates data between the CAN connections. It is typically violet. Feature Feature Description Description CAN output—male This connects to the next node in the chain or the terminating resistor. CAN input—female This connects to the previous node in the chain or the discharge CANbus connector on the control box. -
Page 24: 2.0 Meter Can Cable
Safety Introduction Overview Installation Operation Maintenance 2.0 Meter CAN Cable The CAN cable communicates data between the CAN connections. It is typically violet. The CAN cable is not interchangeable with the sensor cable. You can connect 2 or more cables together to achieve a desired length. 6.56 ft Feature Feature... -
Page 25: 0.5 Meter Can Cable
Safety Introduction Overview Installation Operation Maintenance 0.5 Meter CAN Cable The CAN cable communicates data between the CAN connections. It is typically violet. The CAN cable is not interchangeable with the sensor cable. You can connect 2 or more cables together to achieve a desired length. 19.68 in 500 mm Feature... -
Page 26: 3.0 Meter Sensor Cable
Safety Introduction Overview Installation Operation Maintenance 3.0 Meter Sensor Cable The sensor cable communicates data between the various connections. It is typically yellow, gray, or black. The sensor cable is not interchangeable with the CAN cable. You can connect 2 or more cables together to achieve a desired length. 9.84 ft Feature Feature... -
Page 27: 0.5 Meter Sensor Cable
Safety Introduction Overview Installation Operation Maintenance 0.5 Meter Sensor Cable The sensor cable communicates data between the various connections. It is typically yellow, gray, or black. The sensor cable is not interchangeable with the CAN cable. You can connect 2 or more cables together to achieve a desired length. 19.68 in 500 mm Feature... -
Page 28: Manual Override Power Relay Panel Cable
Safety Introduction Overview Installation Operation Maintenance Manual Override Power Relay Panel Cable 11.81 in 300 mm Feature Feature Description Description M12 connector This connects to the override relay connector on the control box or a sensor cable connected to the control box. Cable This is a yellow cable jacket. -
Page 29: Concentrate Pump Cable
Safety Introduction Overview Installation Operation Maintenance Concentrate Pump Cable 11.81 in 300 mm Feature Feature Description Description M12 connector This connects to the concentrate pump connector on the control box or a sensor cable connected to the control box. Cable This is a yellow cable jacket. -
Page 30: Concentrate Pump Cable-Schematic
Safety Introduction Overview Installation Operation Maintenance Concentrate Pump 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 Connector Connector 1 Vcc, +24 V A Signal 2 Signal B Vcc, +24 V 3 Ground... -
Page 31: Hydraulic Pump Cable
Safety Introduction Overview Installation Operation Maintenance Hydraulic Pump Cable 11.81 in 300 mm Feature Feature Description Description M12 connector This connects to the hydraulic pump connector on the control box or a sensor cable connected to the control box. Cable This is a yellow cable jacket. -
Page 32: Hydraulic Pump Cable-Schematic
Safety Introduction Overview Installation Operation Maintenance Hydraulic Pump Cable—Schematic Brown Brown White White Blue Blue Black Black Gray Gray M12 Connector M12 Connector Connector 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 PWM return—CD 5 Shield... -
Page 33: Concentrate Tank Level Cable-Installer-Supplied
Safety Introduction Overview Installation Operation Maintenance Concentrate Tank Level Cable—Installer-Supplied Feature Feature Description Description M12 connector This connects to the tank level connector on the control box or a sensor cable connected to the control box. Tank level sensor connector This connects to the installer-supplied tank level system. -
Page 34: Concentrate Tank Level Cable-Schematic
Safety Introduction Overview Installation Operation Maintenance Concentrate Tank Level Cable—Schematic 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 Phoenix Contact—1405879 or equivalent... - Page 35 Notes...
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Page 36: Installation Overview
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 Overview Installation Operation Maintenance 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
Safety Introduction Overview Installation Operation Maintenance Electrical and Cable Connections... - Page 39 Safety Introduction Overview Installation Operation Maintenance Electrical and Cable Connections 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. Terminal block This allows you to distribute multiple power circuits from one supply—installer-supplied.
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Page 40: Plumbing Layout
Safety Introduction Overview Installation Operation Maintenance Plumbing Layout Use the illustration as a guide to lay out the plumbing connections in your application. - Page 41 Safety Introduction Overview Installation Operation Maintenance 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 contamination to the concentrate during testing and training.
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Page 42: Connecting Power To The Control Box
Safety Introduction Overview Installation Operation Maintenance Connecting Power to the Control Box Use the illustration and instructions to power the control box. All hardware required to power the control box is provided by the installer. Before you begin, determine the number of PLCs within the control box and prepare a wire harness for each. -
Page 43: Installing The Optional Manual Override
Safety Introduction Overview Installation Operation Maintenance Installing the Optional Manual Override Use the illustration and instructions to connect the optional manual override panel and power relay panel. 1 To install the manual override panel, do the following: • Install the manual override panel onto the apparatus. -
Page 44: Wiring The Source-Select Switch
Safety Introduction Overview Installation Operation Maintenance 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 45: Connecting Pump Discharge Pressure Sensor
Safety Introduction Overview Installation Operation Maintenance 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—pump pressure connector. -
Page 46: Connecting The Node Controllers
Safety Introduction Overview Installation Operation Maintenance Connecting the Node Controllers Use the illustration and instructions to connect the node controllers to the control box. 1 Connect the CAN cable splitter to the CAN connector on the node controller. 2 Connect the CAN cable splitter to an upstream node controller or to the control box—discharge CANbus connector. -
Page 47: Connecting The Control Panel
Safety Introduction Overview Installation Operation Maintenance Connecting the Control Panel Use the illustration and instructions to connect the control panel to the control box. 1 Connect the compatible connector on the Tellurus HMI cable to the control panel connector. 2 Connect the compatible connector on the Tellurus HMI cable to the Tellurus CAN cable. -
Page 48: Connecting The Concentrate Supply Level Sensors
Safety Introduction Overview Installation Operation Maintenance 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 connector. -
Page 49: Connecting The Concentrate Pump, Pressure Sensor, And Source Select Valve
Safety Introduction Overview Installation Operation Maintenance 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 installer-supplied source select valve to the control box. 1 Use a sensor cable to connect the concentrate pump speed sensor to the control box—pump speed connector. -
Page 50: Connecting The Hydraulic Sensors And Hydraulic Pump
Safety Introduction Overview Installation Operation Maintenance Connecting the Hydraulic Sensors and Hydraulic Pump Use the illustration and instructions to connect the hydraulic sensors and hydraulic pump to the control box. 1 Use a sensor cable to connect the temperature sensor to the control box—ATF temperature connector. -
Page 51: Connecting The Manual Override
Safety Introduction Overview Installation Operation Maintenance Connecting the Manual Override Use the illustration and instructions to connect the optional manual override panel and power relay panel. 1 Use the cable on the manual override panel to connect the panel to the control box—manual override switch connector. -
Page 52: Connecting To A Node Controller
Safety Introduction Overview Installation Operation Maintenance 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 Overview Installation Operation Maintenance 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). CAN cable This connects the node controllers to one another and the control box. Node controller This connects to the concentrate control valve, flowmeters, and additional DLAs.
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Page 54: Connecting The 1-Inch Dla And Paddlewheel Flowmeter
Safety Introduction Overview Installation Operation Maintenance Connecting the 1-Inch DLA and Paddlewheel Flowmeter 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 CAN cable splitter to the CAN connector on the node controller. -
Page 55: Connecting The 2-Inch Dla And Paddlewheel Flowmeter
Safety Introduction Overview Installation Operation Maintenance Connecting the 2-Inch DLA and Paddlewheel Flowmeter Use the illustration and instructions to connect the 2-inch DLA to the control box and the paddlewheel flowmeter to the node controller. 1 Connect the CAN cable splitter to the CAN connector on the node controller. -
Page 56: Connecting The Priming Valve
Safety Introduction Overview Installation Operation Maintenance Connecting the Priming Valve Use the illustration and instructions to connect the priming valve to the control box. 1 Connect the CAN cable splitter to the CAN connector on the priming valve power cable. 2 Connect the CAN cable splitter to an upstream node controller or to the control box—discharge CANbus connector. -
Page 57: Connecting The Low-Flow Bypass Line
Safety Introduction Overview Installation Operation Maintenance 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 CAN cable splitter to the CAN connector on the node controller. -
Page 58: Connecting The Supply Tank Fill Line
Safety Introduction Overview Installation Operation Maintenance 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 CAN cable splitter to the CAN connector on the node controller. -
Page 59: Operation
Safety Introduction 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 it. -
Page 60: Maintenance
Safety Introduction 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 excess debris buildup, worn components, or any developing leaks. Consider environmental conditions, hours of operation, and other factors specific to your application to develop a suitable maintenance 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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