Aquastorm 200 Installation Manual

7/31/2019 Aquastorm 200 Installation Manual

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Aquastorm 200

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Manual Part Number2-9316-646-00-0

Text Part Number2-9316-645-00-0

Installation Manual

Copyright 1996 Electrovert

No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any

means: electronic, mechanical, photocopying, recording, scanning, or otherwise without the prior written

permission of Electrovert.

Published, October 25, 1996 by:

Electrovert U.S.A. Corp.

Aquastorm 200Aqueous Cleaning System


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Electrovert U.S.A. Corp.

P.O. Box 709, Highway 5 South

Camdenton, MO 65020-0709

ELECTROVERT

The Serial Tag information is to be filled in by the user for Technical Support purposes. Please have this

information available when contacting Technical Support or when placing parts orders.


3/70iii

A q u a s t o r m 2 0 0

IN TRO DU CTIO NIN TRO DU CTIO NIN TRO DU CTIO NIN TRO DU CTIO NIN TRO DU CTIO NC o n g r a tu l at io n s o n y o u r p u r c h a se o f an A q u a st o r m 2 0 0 A q u e o u s C l e an i n g Sy st e m . T h e A q u a st o r m 2 0 0 i s a p o w e r f u le f fi cie n t a q u e o u s c le a n e r d e sign e d fo r t h e re m o v a l o f c o n ta m in a te d f lu id s an d p a r t i cle s le ft b e h in d f ro m w a v e so ld e r in g an d /o r r e f lo w p r o c e s se s o n c o m p l e x su r f ac e m o u n t a n d m i xe d t e c h n o l o g y P W A s . E ac h se c t io n o f t h e A q u a st o r m 2 0 0 h abee n care fu l ly in tegra ted and b a lanced to ach ieve the bes t c lean ing and d r y ing capab i l ity fo r i ts size and co s t , ava ilab le in th eindus t ry .

T h e p u rp o se o f t h is m a n u a l is t o h e lp o b ta in th e g re a te s t p o s sib le re tu rn o n y o u r i n v e s tm e n t . I t is su g g e ste d th a t n e wo p e ra to rs stu d y th e a p p l i ca b le s e c t io n s o f t h i s m a n u a l t h o ro u g h ly b e fo re o p e ra t in g th e e q u ip m e n t . I t i s f u r th e r s u g ge s te d

th a t t h e m a n u al b e u s e d a s a re fe re n c e b y m a in te n a n c e p e r so n n e l a n d a s a te x t fo r t r a in in g o f n e w m a in te n a n c e p e rs o n n e l

T h is m a n u a l i n c lu d e s o p e ra t in g in st ru c t io n s fo r t h i s e q u ip m e n t a v a ilab le a t t h e t im e th i s m a n u al w a s a p p ro v e d fo r p r in t i n gE le c t ro v e r t r e s e rv e s th e r i g h t t o m a ke c h a n g e s in d e s ig n a n d s p e c if ic at io n s an d /o r m a k e ad d i t i o n s to o r im p ro v e m e n ts in th e

p ro d u c t w i th o u t im p o sin g a n y o b l iga t io n s u p o n i t se l f t o i n s tal l t h e m o n p re v io u sly m a n u fa ctu re d p ro d u c ts .

Electro vert Sa les an d Service O fficesElectro vert Sa les an d Service O fficesElectro vert Sa les an d Service O fficesElectro vert Sa les an d Service O fficesElectro vert Sal es a nd Service O ffices

R e g i o n a l S e r v i c e C e n t e r sR e g i o n a l S e r v i c e C e n t e r sR e g i o n a l S e r v i c e C e n t e r sR e g i o n a l S e r v i c e C e n t e r sR e g i o n a l S e r v i c e C e n t e r s

N o r t h E ast R e g io n a l Se r v i ce C e n t e r

4 7 2 A m h e r s t St . Su i t e 6N ash u a, N H 0 3 0 6 3

F a x : 6 0 3 - 8 8 0 - 8 7 5 7

T e l : 6 0 3 - 8 8 3 - 2 4 8 8

South East Reg io na l Serv i ce C ente r2 0 0 Te c h n o l o g y D r.

A l p h ar e t t a, G A 3 0 0 0 5F a x : 7 7 0 - 4 4 2 - 1 9 8 7T e l : 7 7 0 - 4 7 5 - 6 1 0 0

N o r t h C e n t r al R e gio n a l Se r v ic e C e n t e r580-A To l lga te Road

E lg in , I L 601 23F a x : 8 4 7 - 2 8 9 - 3 7 9 7

T e l : 8 4 7 - 6 9 5 - 5 7 5 0

N o r t h W e st R e gio n a l Se r v ic e C e n t e r2 9 6 8 S co t t B lvd .Sa n t a C l ar a , C A 9 5 0 5 4F a x : 4 0 8 - 7 2 7 - 0 6 7 2

T e l : 4 0 8 - 7 2 7 - 4 6 5 0

So u t h W e s t Re g io n a l Se r v i ce C e n t e r

1 1 1 1 W . N o r t h C ar r ie r Pa rk w ayG r a n d Pr a ir ie , T X 7 5 0 5 0

F a x : 9 7 2 - 6 0 6 - 1 7 0 0

T e l : 9 7 2 - 6 0 6 - 1 9 0 0

E le c t r o v e r t M a in O ffic e sE le c t r o v e r t M a in O ffic e sE le c t r o v e r t M a in O ffic e sE le c t r o v e r t M a in O ffic e sE le c t r o v e r t M ai n O ffi ce s

Pr o d u c t & T e ch n o lo g y C e n t e rE le c t r o v e r t U S A C o r p .

1 1 1 1 W . N o r t h C a rr ie r Par k w a yG r a n d Pr a ir ie , T X 7 5 0 5 0

F a x : 9 7 2 - 6 0 6 - 1 7 0 0T e l : 9 7 2 - 6 0 6 - 1 9 0 0

Te ch n i cal Se r v i ce Su p p o r t G r o u p &C u s to m e r S e r v ic e Pa r ts D e p a r tm e n t

E le c t r o v e r t U S A C o r p .P. O . B o x 7 0 9C a m d e n to n , M O 6 5 0 2 0

F a x : 5 7 3 - 3 4 6 - 6 8 7 8T e l : 5 7 3 - 3 4 6 - 3 3 4 1

E d u ca ti o n a l Se r v i ce s & C u s t o m e r S u p p o r tC e n t e r

5 8 0 - A To l l ga t e R o a dE lg in , I L 60123F a x : 8 4 7 - 2 8 9 - 3 7 9 7

T e l : 8 4 7 - 6 9 5 - 5 7 5 0

I n t e r n a t i o n a l S e r v i c e C e n t e r sI n t e r n a t i o n a l S e r v i c e C e n t e r sI n t e r n a t i o n a l S e r v i c e C e n t e r sI n t e r n a t i o n a l S e r v i c e C e n t e r sI n t e r n a t i o n a l S e r v i c e C e n t e r s

N o r t h er n Eu r o p e & U . K.E le c t r o ve r t U . K . L t d .

T h e Te c h n o l o g y C e n t r eU n i t 1 , P incen ts K i ln I ndust r ia l Park

Pincen ts K i lnC a lco t , R e a d i n g

B e r ks ., U . K . R G 3 1 7 SOFa x: 4 4 1 1 - 8 - 9 3 0 - 1 4 0 1T e l : 4 4 1 1 - 8 - 9 3 0 - 1 4 0 0

E lec t rover t S ingapore1 0 K i an T e ck C r e sce n t

Sin g ap o r e 6 2 8 8 7 6Fa x : 6 5 - 8 6 1 - 7 3 3 7

Te l : 6 5 - 8 6 1 - 1 6 6 1

Japan

E le c t r o ve r t - S e it e c C o . , L t d .1 5 3 8 K a n o y a- c h oH ach io j i C i t y, To kyo 1 93 JAPAN

F a x : 8 1 - 4 2 6 - 2 3 - 8 3 5 0T e l : 8 1 - 4 2 6 - 2 3 - 7 7 2 2

N o r t h e r n Eu r o p eSpeed l ine Techn o log ies S .A .R.L .

6 5 A v e n u e d u G e n e r a l D e G a u lleI m m e u b l e le Pr o m e t h e e

7 7 4 2 0 C h a m p s - Su r M a r n e , Fr a n ceFa x : 3 3 1 6 0 - 0 5 - 6 1 2 9Te l : 3 3 1 6 0 - 0 6 - 8 1 8 1

C e n t r a l E u r o p eSp e e d l in e T e ch n o l o g i e s, G m b h

D a im le r st r asse 1 E D - 6 3 3 0 3D r e i e ic h , G e r m a n y

Fa x: 4 9 6 1 0 3 - 8 3 2 1 1 9Te l : 4 9 6 1 0 3 - 8 3 2 0

Speed l ine Techn o log ies It a lyV ia L igur ia 2 /2 8I - 2 0 0 6 8 Pe sc h ie r a B o r r o m e o ( M I )

I talyFa x :3 9 - 2 - 5 5 3 0 . 8 4 6 8

Te l : 3 9 - 2 - 5 5 3 0 . 8 3 3 9


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TABLE OF CONTENTS

SECTION 1 GENERAL ................................................................................................................................... 11.1 HAZARDS ........................................................................................................................................................... 11.2 SAFETY PRECAUTIONS ....................................................................................................................................... 3

SECTION 2 Technical Data ........................................................................................................................................... 52.1 Facility Requirements ........................................................................................................................................... 5

Water Requirements ..................................................................................................................................... 5Final Rinse ................................................................................................................................................... 5Fill .............................................................................................................................................................. 5System Drain ................................................................................................................................................ 5Exhaust Requirements ................................................................................................................................... 5Electrical Requirements ................................................................................................................................. 6Reference Schematics ................................................................................................................................... 6Power .......................................................................................................................................................... 6Capacities ................................................................................................................................................... 7Specifications ............................................................................................................................................... 7

2.2 Dimensions ......................................................................................................................................................... 8

SECTION 3 Installation Preparation ............................................................................................................................ 113.1 Receiving Instructions ......................................................................................................................................... 11

3.2 Installation Planning .......................................................................................................................................... 11System Footprint Drawing................................................................................................................................... 123.3 Installation Check List ........................................................................................................................................ 13

SECTION 4 Equipment / Tools Required ...................................................................................................................... 144.1 Protective Clothing ............................................................................................................................................ 144.2 Tools and Materials ........................................................................................................................................... 144.3 Expendable Items .............................................................................................................................................. 144.4 Rigging Equipment ............................................................................................................................................ 144.5 Maintenance ..................................................................................................................................................... 14

SECTION 5 Shipping Arrangement ............................................................................................................................. 155.1 Shipping Weights and Dimensions ...................................................................................................................... 15

Domestic Shipment Dimensions .......................................................................................................................... 15

5.2 Packaging Configuration.................................................................................................................................... 16Domestic Shipments Packaging Arrangement ....................................................................................................... 16International Shipments Packaging Arrangement .................................................................................................. 17

SECTION 6 Unpacking Procedures (Domestic Shipments Only) .................................................................................... 196.1 Installing the System Leveling Feet....................................................................................................................... 196.2 Removing the system Packaging Materials ........................................................................................................... 21

SECTION 7 Crate Dismantling Procedures (International Shipments Only) ................................................................... 237.1 Installing the System Leveling Feet....................................................................................................................... 27

SECTION 8 Installation / Set-Up ................................................................................................................................. 28

8.1 Positioning the Aquastorm 200 ............................................................................................................................................................................................. 28

8.2 Main Cabinet Leveling Procedure ....................................................................................................................... 29

8.3 Removing the System Packaging Materials........................................................................................................... 308.4 Installing the Drain Screens ................................................................................................................................ 328.5 Optional Sump Pump Installation ....................................................................................................................... 338.6 Optional Treatment Interface Installation ............................................................................................................. 358.7 Optional Inlet Conveyor Installation .................................................................................................................... 378.8 Optional Photocell Hook-Up .............................................................................................................................. 398.9 Bolt On Sound Enclosure Installation (Crated Shipments Only) .............................................................................. 408.10 Conveyor Wire Belt Installation (Crated Shipments Only) ...................................................................................... 428.11 Wire Belt Splicing Instructions ............................................................................................................................. 458.12 Pump Drain Plug Installation .............................................................................................................................. 508.13 Facility Connections .......................................................................................................................................... 51

Facility Water Hook-Up ..................................................................................................................................... 51Rinse Hose ....................................................................................................................................................... 52Facility Exhaust Hook-Up ................................................................................................................................... 53Facility Power Connection .................................................................................................................................. 54


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8.14 System Electrical Check...................................................................................................................................... 57Main Power ...................................................................................................................................................... 57Secondary Voltage ............................................................................................................................................ 58

8.15 Motor Rotation Check........................................................................................................................................ 61Other ............................................................................................................................................................... 64


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LIST OF FIGURES

SECTION 2

Figure 1 - Cabinet Dimensions.................................................................................................... 8Figure 2 - Inlet Conveyor Dimension ........................................................................................... 8Figure 3 - Treatment Interface Dimensions.................................................................................... 9Figure 4 - Sump Pump Dimensions .............................................................................................. 9

SECTION 3

Figure 7 - Aquastorm 200 System Footprint Layout Drawing ..................................................... 12

SECTION 5

Figure 8 - Domestic Packaging Arrangement .............................................................................. 16Figure 9 - Documentation Package ........................................................................................... 16Figure 10 - Crated System ........................................................................................................ 17Figure 11 - System Documentation Package ............................................................................... 18

SECTION 6

Figure 13 - Leveling Feet in Documentation Package .................................................................. 19Figure 14 - Leveling Foot .......................................................................................................... 19Figure 16 - System with Protective Plastic Wrapping .................................................................... 21Figure 17 - Tank Packaging ...................................................................................................... 21Figure 18 - Exit End Packaging.................................................................................................. 22Figure 19 - Optional Sink Packaging ......................................................................................... 22

SECTION 7

Figure 20 - Crate Dismantling ................................................................................................... 23

Figure 21 - Crate Dismantling ................................................................................................... 23Figure 22 - Crate Opened........................................................................................................ 24

Figure 28 - Documentation Package ......................................................................................... 27Figure 29 - Leveling Foot .......................................................................................................... 27

SECTION 8

Figure 31 - Leveling Foot Adjustment ......................................................................................... 29Figure 32 - Twelve Leveling Feet Locations ................................................................................. 29Figure 33 - Removing the Plastic Wrap ...................................................................................... 30Figure 34 - Removing the foam padding from the windows ......................................................... 30Figure 35 - Tank Packaging ...................................................................................................... 31

Figure 36 - Sound Enclosure and Tool Kit Door Packaging .......................................................... 31Figure 37 - Optional Sink Packaging ......................................................................................... 31

Figure 38 - Documentation Package ......................................................................................... 32Figure 39 - Drain Screen .......................................................................................................... 32Figure 40 - Prewash Drain Screen Location ................................................................................ 32

Figure 41 - Tank Drain Screen Locations .................................................................................... 32Figure 42 - Sump Pump Installation ........................................................................................... 34

Figure 43 - Treatment Interface Installation ................................................................................. 36Figure 44 - Inlet Conveyor Installation ....................................................................................... 38Figure 45 - Photocell Mounting ................................................................................................. 39Figure 63 - Sound Enclosure Installation .................................................................................... 40


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Figure 46 - Wire Belt Installation ............................................................................................... 42

Figure 47 - Feeding the Wire Belt .............................................................................................. 43Figure 48 - Wire Belt Master Links ............................................................................................. 44

Wire Belt Splicing Photographs ................................................................................................ 45 - 47

Photograph 1 .......................................................................................................................... 45Photograph 2 .......................................................................................................................... 45Photograph 3 .......................................................................................................................... 46Photograph 4 .......................................................................................................................... 46Photograph 5 .......................................................................................................................... 47Photograph 6 .......................................................................................................................... 47Photograph 7 .......................................................................................................................... 47

Wire Belt Company of America Illustrations............................................................................... 48 - 49Illustration 1 - 3 ....................................................................................................................... 48Illustration 4 - 7 ....................................................................................................................... 49

Figure 50 - Facility Exhaust Connections .................................................................................... 53Figure 51 - Ground Connections .............................................................................................. 54

Figure 52 - Serial Tag, Conduit Connector, and Incoming Power Locations ................................... 55Figure 53 - Main Power Connections......................................................................................... 56Figure 54 - System Serial Tag .................................................................................................... 57Figure 55 - Secondary Voltage Testing ....................................................................................... 58Figure 56 - Clamp Ammeter ..................................................................................................... 59Figure 57 - High Voltage Panel Layout/ Test Points ...................................................................... 60Figure 58 - Control Panel Quick Reference ................................................................................ 61Figure 59 - Rear View of Blower Location................................................................................... 62Figure 60 - Blower Rotation Tag ................................................................................................ 62Figure 61 - Control Panel Quick Reference ................................................................................ 62

Figure 62 - Power Phasing ........................................................................................................ 63


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General 1

DANGER High Voltage:

Installation of this equipment involves exposure to High Voltage. High voltage can shock, burnor cause death. Use extreme caution when performing voltage and amperage tests on livevoltage. These procedures must be performed only by an authorized electrician, electricalengineer or service technician familiar with testing live voltage.

SECTION 1 GENERAL

1.1 HAZARDS

Operation of this equipment exposes personnel to potential health hazards.

WARNING Risk of Electric Shock:

Installation of this equipment exposes personnel to situations which may result in electrical

shock if procedures are not properly followed. Pay close attention to Warnings of this naturethroughout the context of this manual.

When performing tests using ammeters, volt meters or ohm meters, electrical shock hazard ispresent. These procedures must be performed only by an authorized electrician, electricalengineer or service technician familiar with testing live voltage.

WARNING Skin Irritation:

When using certain chemicals such as descalers or saponifiers, it is important to follow the

MSDS (Material Safety Data Sheet) guidelines for proper handling and usage. Appropriateclothing and safety articles must be worn when using descaler and saponifier solutions. Skin oreye irritation will occur if not handled properly.


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2 General

WARNING Hot Surfaces/Burn Hazard:

During normal operation this equipment and some of its components operate at temperatures

up to 60-71o

C (140-160o

F). The operator must use extreme caution and wear therecommended safety garments prior to coming in contact with hot surfaces or components.Closely follow and adhere to the Warnings in this manual which pertain to hot surfaces.

Use extreme caution when working around or with hot components. Allow hot components tocool before handling whenever possible.

WARNING Heavy Objects:

When attempting to move heavy equipment or components, it is imperative to use the properrigging equipment. Do not attempt to move skids or large assemblies without the use of a forklift or other rigging equipment. Hand lifting will cause serious personal injury.


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General 3

1.2 SAFETY PRECAUTIONS

Electrical work should only be performed by a qualified electrician.

Prior to applying power for the first time, ensure that the system is properly grounded.

Post "NO SMOKING" signs in the work area and provide measures for enforcement.

Exercise Caution when using strong cleaning agents, solvents and other chemicals. Material Safety Data

Sheets (MSDS) contain specific uses and safety precautions which must be thoroughly understood and

strictly followed. If in doubt about any Caution, contact the manufacturer for clarification.

Avoid prolonged skin contact and inhalation of chemicals and fumes.

Operating this equipment may introduce burn hazards. Avoid contact with all hot surfaces, hot water and

steam. The viewing glass will reach temperatures in excess of 71o C (160o F). Extreme caution should be

taken to avoid touching the glass surfaces. Water temperatures will reach and/or exceed 71

o

C (160

o

F)Steam may escape from the system cabinet when windows are opened during operation or for maintenance

procedures. Steam will cause serious burns. Avoid contact with steam.

Protective clothing is required for servicing hot machine components or areas of the machine which come in

contact with chemical applications . Protective clothing includes ANSI (American National Standard Institute)

approve Safety Goggles, NIOSH or MSHA Approved Respirator, Steel Toe Safety Shoes, High Temperature

Acid and Water Resistant Gloves, Apron and a Long-Sleeved garment.

Fumes can be generated from certain saponifiers, defoamers, descalers, cleaning solvents, etc., during

operation. Precautions must be taken to avoid accumulation of flammable vapors. Whenever harmful fumes

are present, a proper extraction (exhaust) system must be provided. Refer to the manufacturer MSDS for

information and safety precautions concerning their products and system exhaust specifications.

Refer to specific Chemical Manufacturers Material Safety Data Sheets for disposal and/or removal and

handling of waste materials resulting from chemical operating processes.

Under the previously mentioned circumstances, all operators should be provided with an NIOSH or MSHA

Approved Respirator, to provide the operator effective protection from airborne residue resulting from

certain saponifiers, defoamers, descalers, cleaning solvents, etc.

NOTE: The above mentioned types of chemicals and cleaning agents recommended for

use with the Aquastorm 200 are not products of Electrovert. Please refer to

the specific chemical manufacturers MSDS (Material Safety Data Sheets) forthe specific use, handling, and safety procedures for their applications.


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4 General

WARNING Warning notices are used in this manual to emphasizehazardous voltages, high currents, high temperatures orother conditions that could cause personal injury.

DANGER Danger notices are used in this manual to warn theoperator that DEATH may result if a procedure is omittedor improperly performed.

CAUTION Caution notices are used to call attention to a situationthat could cause damage to the equipment.


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Aquastorm 200

Technical Data 5

2.1 FACILITY REQUIREMENTS

Water Requirements

NOTE The Fill and Final Rinsewater supplies must be

separate.

NOTE The immersion heaters in

the Recirculating Wash

and Rinse tanks will heat

incoming tap or treated

water after an initial

waiting period.

Electrovert recommendssupplying heated water 60

- 71o C (140 - 160o F) to

the Recirculating Wash,

Rinse, and optional

chemical isolation tanks in

order to maintain

operating temperatures.

Final Rinse

Schedule 80, 3/4" NPT, CPVC pipe

User supplied, heated tap or treated water to

Final Rinse.

Temperature 60 - 71o C (140 - 160o F)

Flow Rate 11 - 19 L/Min (3 - 5 Gal./Min..)

Nominal Pressure 2.8 - 3.3 kg/cm2

(35 - 40 PSI)

Fill

Schedule 80, 3/4" NPT, CPVC pipe

Heated water to 60 - 71o C (140 - 160o F)

System Drain

Common 1 1/2" NPT, CPVC pipe;

38 L/Min. (10 GPM) constant

SECTION 2 TECHNICAL DATA

Exhaust Requirements

NOTE The following exhaustspecifications are to assist

the customer in specifying

an exhaust blower capable

of exhausting the system

All exhaust

measurements are

measured at the machine

exhaust port.

NOTE An independent, separate

blower is recommended

for this equipment due to

the high volume

requirements and

condensate build up

resulting from normal

operation of this

equipment.

Contact your local HVAC

specialist for blowerrequirements and

ventilation hook-up.

Recommended venting material - 25.4 cm (10 ")

diameter, seamless stainless steel or PVC air duct

Total system requires 68M 3/min. @ 2.5 cm

(2400 SCFM @ 1") H2O static pressure.

Port #1 - 34M 3/min. @ 2.5 cm (1200 SCFM

@ 1.0") H2O static pressure.

Port #2 - 34M 3/min. @ 2.5 cm (1200 SCFM

@ 1.0" ) H2O static pressure.


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Aquastorm 200

6 Technical Data

PowerStandard Configuration

Voltage F.L.A. Total KVA Recommended Service

220 VAC, 60 Hz 264 100.6 325

380 VAC, 50 Hz 152 100.6 200

460 VAC, 60 Hz 126 100.6 150

Pump and Blower Upgrade Level 1 Configuration

NOTE This configuration upgrades the Wash and Rinse pumps to 10 HP; Dryer blowers

to 10 HP; adds an IR Dryer to Dryer #2; adds a 7.5 HP Enhanced ChemicalIsolation blower and a tank immersion heater.


220 VAC, 60 Hz 315 120 400

380 VAC, 50 Hz 182 120 250

460 VAC, 60 Hz 150 120 200

Pump and Blower Upgrade Level 2 Configuration

NOTE This configuration upgrades the Wash and Rinse pumps to 10 HP; adds an IRDryer to Dryer #2; the blower in Dryer #1 is upgraded to 15 HP; adds the

Enhanced Chemical Isolation tank immersion heater.


220 VAC, 60 Hz 360 136 450

380 VAC, 50 Hz 206 136 275

460 VAC, 60 Hz 171 136 225

Electrical Requirements

Standard Electrical Configuration:

460 VAC, 3 PH, 60 Hz

Optional Electrical Configuration:

220 VAC, 3 PH, 60 Hz

380 VAC, 3 PH, 50 Hz

Reference Schematics

VOLTAGE DRAWING #

460V, 60Hz 8-1679-006-01-2

220V, 60Hz 8-1679-005-01-2

380V, 50Hz 8-1679-003-01-2

Panel Layout 8-1679-004-01-2

NOTE It is the responsibility of

the customer to provide a

system electrical

disconnect capable of

protecting the Aquastorm

200 at the amperages

specified for 220 V

electrical configurations.System disconnects are

only provided with 380

and 460 V systems.


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Aquastorm 200

Technical Data 7

Capacities

Recirculating Wash Tank - 300 Liter (80 gallon)

Optional Enhanced Chemical Isolation Tank -

95 Liter (25 gallon)

Recirculating Rinse Tank - 189 Liter (50 gallon)

Optional Sump Pump - 38 Liter (10 gallon)

Optional Treatment Interface Tank - 66.24 Liter

(17.5 gallon)

Specifications

Wash Pump -

Standard - 5 HP @ 220 L/Min. (58 gpm)

Hurricane - 10 HP @ 439 L/Min. (116 gpm)

Wash Heaters - (2) 16 KW Heaters; 32 KWTotal

Optional Enhanced Chemical Isolation

Tank Heater - (1) 16 KW Total

Rinse Pump -

Standard - 5 HP @ 220 L/Min. (58 gpm)

Hurricane - 10 HP @ 439 L/Min. (116 GPM)

Rinse Heaters - (2) 16 KW Heaters; 32 KW

Total

Optional Drag-Out Blower - 7.5 HP, 3 Ph

460 VAC, 500 CFM Turbine Blower

Dryer #1 Blower -

Standard - 7.5 HP, 3 Ph, 460 VAC , 500 CFM

Turbine Blower

Option 1 - 10 HP, 3 Ph, 460 VAC, 600 CFM

Turbine Blower


Turbine Blower

Dryer #2 Blower -

Standard - 7.5 HP, 3 Ph, 460 VAC , 500 CFM

Turbine Blower


Turbine Blower

Optional Radiant Heater - (2) 1800 Wat

Radiant Heater panels; 3.6 KW Total

Conveyor - 1/8

HP, 90 VDC Motor, 0 - 3.65

MPM (0-12 FPM) (0 - 4.57 Meters/Min.)

CheckMate Conveyor - (2), 1/8

HP, 90 VDC

Motors, 0-15 FPM (0 - 4.57 Meters/Min.)

Sump Pump - 3/4

HP, 3 pH, 460 VAC, 50

gpm (189 L/Min.)


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Aquastorm 200

8 Technical Data

2.2 DIMENSIONS

Main Cabinet [Frame] - 600 cm (236.38")

L x 154 cm (60.51") W x 128 cm

(50.24") H

Main Cabinet, Control Panel, and Sound

Enclosure overall dimensions - 691 cm

(272")

Leveling Feet - 10.16 cm (4")

Optional Inlet Conveyor 85.8cm (33.8")

600 cm

(236.38")

5 cm (2

128 cm

(50.24")

154 cm

(60.51")

691 cm (272")

5 cm (2.0")

10.16 cm (4.0")

Optional Status Tower - 58.9cm (23.2")

from top of Main Cabinet

Exhaust Vent - 5 cm (2.0") from the top ofthe Main Cabinet

91.44 cm(36.0")

Figure 1 - Cabinet Dimensions

Figure 2 - Inlet Conveyor Dimension


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Aquastorm 200

Technical Data 9

133.6 cm (52.1")

68.3 cm (26.7")

81.62 cm (32.13")

Optional Treatment Interface system -

133.6 cm (52.1") L x 68.3 cm (26.7") W x 81.62

cm (32.13") H

Optional Sump Pump -

61.6 cm (24") L x 42.5 cm (16.6") W x

61.8 cm (24.1") H

Figure 3 - Treatment Interface Dimensions

Figure 4 - Sump Pump Dimensions


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Installation Preparation 11

Aquastorm 200

SECTION 3 INSTALLATION PREPARATION

3.1 RECEIVING INSTRUCTIONS

Upon receipt, the system should be thoroughly

inspected. If damage or loss are detected, enter

all details on the freight bill or receipt, then have

it signed by the carrier's agent. Failure to follow

this procedure may result in the carrier's refusal

to honor the claim. The carrier will furnish the

necessary forms for filing a claim.

When damage is not readily apparent until the

equipment has been unpacked, a claim for

concealed damage must be filed. Make a written

or telephone request to the carrier for inspection

as soon as the damage is discovered. This type ofclaim must be done within 48 hours of delivery.

Keep all cartons, packing materials and

paperwork. The carrier will furnish an inspection

report and the necessary forms for filing the

concealed damage claim.

3.2 INSTALLATION PLANNING

Al locate suff ic ient floor space to operate

efficiently and to allow accessibility to the system

from all sides. Refer to the system footprint

drawing supplied with the Documentation

Package.

Domestic shipments are on wheels, whereas

International shipments are on skids and in

wooden crates. The system leveling feet are

packaged in a separate container within the

shipment on domestic shipments.

System operation and maintenance functionsrequire additional space for system access. Allow

for an additional 0.9 meters (3 feet) clearance

behind and around the system, except where the

system is in-line with other automated equipment

i.e., wave/reflow soldering equipment. Refer to

the system footprint drawing on the following

page.

In selection of the site location, keep in mind the

requirements that must be provided at the site

i.e., electrical access, facility exhaust, drain, leve

surface, etc.

When considering a site for installation, it is also

important to check the flammability of the

materials to be used during operation or

maintenance, so as to provide adequate protection

for the system as well as personnel protection.

Note that in many instances the process of

cleaning can involve potentially hazardous liquid

materials requiring special handling and

treatment prior to disposal.


18/70

12 Installation Preparation

Aquastorm 200

LightStatusT o

wer(Optional) C

on

veyorExtension

(Optional)

Inlet

Connections

1537

(59.9)

Fram

e

1060

(41.3)

105

(4.1)

20

(.8)

1276

(49.8)

58

9

(23.0)

1

327

(5

1.8)

1185

(46.2)

842

(32.8

)

248

(9.7

)

102/127

(4.0

/5.0)

AdjustableLe

gs

457

(17.8

)

Con

trolPanel

194

(7.6)

1175

(45.8)

54

8

(21.4)

Prewash

55

9

(22.0)

1059

(41.3)

Wash

1219

(48.0)

Chem

icalIso.

889

(35.0)

1095

(42.7)

1054

(41.1

)

6004

(234

.2)

Frame7

478

(291.6)

7540

(29

4.1)

5944

(231.8)

Rinse

1219

(48.0)

Electric

alCabinet

Access

Area

ElectricalCa

binet

AccessArea

267

(10.5)

ExhaaustP o

rt

(2PL)

11

56

(45.1)

SystemD

rain

1056

(41

.2)

1238

(48.3)

43

(1.7)

135

(5.3)

842

(32.8)

Exit

Disconn

ect

Elec.Conn.

3"Co

nduit

508

(19.8)

Final

Rinse

432

(17.0)

Dryer#1

756

( 29.8)

Dryer#2

752

(29.6

)

1820

(71.0)

60

(2.3)

831

(32.4)

Elec.

Conn.

3"Conduit

CLSD

rain(Optional)

FinalRinseLine

FillLine

ToRinse

Ex t

.FeedC.I.

Line(Op

tional)

SplitFillLine

ToW

ash

(Optional)

305

(11.9) 7

87

(30.7)

1105

(43.1)

1375

(53.6

)

Std.Drain

Blower

Slide

Ac

cess

Area 6

10

(23.8)

445

(17.4)

445

(17.4)

1518

(59.2)

BlowerSlide

AccessArea

1903

(74.2)

2985

(116.5)

610

(23.8)

445

(17.4)

4030

(157.2)

42

70

(166.5)

439

0

(171.2)

4488

(17

5.0)

4584

(178. 8

)

5359

( 209.0)

6743/6681

(265.5/

263.0)

137/75

(5.4/3.0)

1575

(61.4)6

32

(24

.6)

StandardInletConv e

yor

Figure7-

Aquastorm2

00S

ystemF

ootprintLa

youtDrawing


19/70


Aquastorm 200

3.3 INSTALLATION CHECK LIST

The following check list is provided for organizational and record keeping

purposes. Failure to record problems with installation or factors required for

proper installation may result in unscheduled down time.

INSTALLATION CHECK LIST

LOCATION SHIPPING DAMAGE

Check For: Check for damage to system:

Adequate floor space

Adequate clearance above and around system

Level surfaces at installation site

Adequated facility connections for

Exhaust

Electrical Hook-Up

System Fill

System Drain

Final Rinse

If any of these requirements are inadequate,please describe:

If damage is found, please describe:

SYSTEM LEVELINGLevel "X" Axis at entrance end of system cabinet

Level "Y" Axis at front of system cabinet

Level "X" Axis at exit end of system cabinet

Level "Y" Axis at rear of system cabinet

Adjust leveling feet and re-check axis on all sides

COMPONENT INSTALLATION

COMPLETE UTILITY CONNECTIONS

DOMESTIC SHIPMENTS

Leveling Feet

Drain Screens

Optional Sump Pump system

Optional Treatment Interface system

Optional Single Add-On Dryer Module

Optional Dual Add-On Dryer Module

Pump Drain Plugs

CRATED SHIPMENTS (International Only)

Conveyor Wire Belt (for crated shipments withOptional Inlet Conveyor)

Optional Inlet Conveyor assembly

Optional Photocell

Drain Screens

Optional Sump Pump and plumbing

Optional Treatment Interface System

Optional Single Add-On Dryer Module

Optional Dual Add-On Dryer Module

Bolt on Sound Enclosure

Exit End Conveyor Drive Assembly

Pump Drain Plugs

Verify system voltage, phase and Hz rating

Check electrical power connections

Check for proper Power connections

Water connections

Drain connections

Exhaust connections

Pump & Blower rotation

NOTES:


20/70


Aquastorm 200

4.1 PROTECTIVE CLOTHING

ANSI (American National Standard Institute)

Approved Safety GlassesSteel Toe Safety Shoes

Acid Resistant Smock

Long-Sleeved Garment

Heat Protective Gloves

4.2 TOOLS AND MATERIALS

Flat Blade Screwdriver

Phillips Head Screwdriver

Channel Lock Pliers

Pipe Wrenches

Teflon Tape

Schedule 80, CPVC Piping

(for Fill - 3/4", Final Rinse - 3/

4", and

Drain - 1 1/2")

Electrician's Pliers

Needle Nose Pliers

Wire Cutters and Strippers

Volt-Ohm Meter

Clamp Ammeter

Carpenter's Level

Allen Wrench (Hex) Set

Adjustable Wrenches (7/16" - 1 1/8")

(For International Shipments the

additional Tools are also required)

Pry Bars

Claw Hammers

Circular Saw (Rip Cut Blade)

4.3 EXPENDABLE ITEMS

Lint-Free Cloths

Glass CleanerSaponifier

Scale Stripper

Defoamer

4.4 RIGGING EQUIPMENT

(Domestic Shipments)

2 Ton Capacity (minimum) Fork Lift

(International Shipments)3 Ton Capacity (minimum) Fork Lift

4.5 MAINTENANCE

Heavy Duty Hose (3/4") Nozzle and Storage Reel

SECTION 4 EQUIPMENT/ TOOLS REQUIRED


21/70


Aquastorm 200

SECTION 5 SHIPPING ARRANGEMENT

Domestic shipments of the Aquastorm 200 are

configured with wheels for easy maneuverability.

The entire system is wrapped in moisture

absorbent polyethylene for protection during

transit.

International (overseas) shipments of the

Aquastorm 200 are skidded and also wrapped

in the moisture absorbent polyethylene for

protection during transit. The system is

encapsulated in a wooden crate to ensure safe

arrival to its destination.

Follow the procedures which apply to your

shipment destination.

It is the responsibility of the customer to provide

any rigging devices required to transport theskidded system to the site of installation.

WARNING Move the Aquastorm 200 systemcrate using a fork lift. This equipmentis extremely heavy and attempting tohand lift will result in personal injury.Transport the Aquastorm 200 system

crate to the site of installation using afork lift.

CAUTION Do Not open crates prior to movingthem to their final site of installationor damage may occur.

5.1 SHIPPING WEIGHTS ANDDIMENSIONS

NOTE This manual makes

reference to both standard

and optional

configurations. Disregard

options which do not apply

to your system

configuration.

Aquastorm 200 systems are shipped as one

unit. Some standard and optional components

are removed from the system prior to shipment

Refer only to installation instructions which apply

to your system configuration.

NOTE All weights and

dimensions are

approximated figures and

are to be used as reference

only.

Domestic Shipment Dimensions

Cabinet Length 684 cm (269")

Cabinet Width 158 cm (62")

Cabinet Height 145 cm (57")


22/70


Aquastorm 200

o Cardboard Box Labeled "Documentation Package Enclosed - Contains the following:

o System Documentation Package

o High Voltage Electrical Schematics

o Control Voltage Electrical Schematics

o System Installation Drawing

o

Instruction Manualo Bill Of Materials (BOM) Manual

o Assembly Drawings

o (2 Sets) Wire Belt Connecting Master Links

o (5) Drain Screens

o (12) Main Cabinet Leveling Feet

o (4) Optional Single Add-On Dryer Module Leveling Feet

o Set of Optional Single Add-On Dryer Module Interface Hardware

o (12) Pads for Leveling Feet

o (4) Pads for Optional Single Add-On Dryer Module Leveling Feet

o (2 Sets) Optional CheckMate Conveyor Connecting Master Links

Domestic Shipments Packaging Arrangement

o Main Cabinet ......................................................................................................................On Wheels

o Optional Add-On Single Dryer Module..................................................................................On Wheels

o Optional Add-On Dual Dryer Module ....................................................................................On Wheels

o Optional Sump Pump .......................................................................................On Van wrapped in pads

o Optional Sump Pump Plumbing, rubber unions and Hose Clamps ....................................... Loose on Van

o Optional Treatment Interface system ................................................................................. Loose on Van

5.2 PACKAGING CONFIGURATION

NOTE This manual makes reference to both standard

and optional configurations. Disregard options

which do not apply to your system configuration.

The following is an itemized list of components removed from the system prior

to shipment for shipping purposes, and how they are packaged so that

components may be easily located and identified:

Figure 8- Domestic Packaging Arrangement

Figure 9 - Documentation Package


23/70


Aquastorm 200

International Shipments Packaging Arrangement

o Main Cabinet ................................................................................................. Bolted to skid and crated

o Optional Add-On Single Dryer Module............................................................. Bolted to skid and crated

o Optional Add-On Dual Dryer Module ............................................................... Bolted to skid and crated

o Roll of Conveyor Wire Belt....................................................... In a cardboard container strapped to skid

o Opitonal Adjustable Inlet Conveyor Extension ............................ In a cardboard container strapped to skid

o Exit End Sound Enclosure ................................................................ Strapped to Skid on inside of crate

o Exit End Conveyor Extension .............................................................Strapped to skid on inside of crate

o Optional Sump Pump system..............................................................Strapped to skid on inside of crate

o Optional Treatment Interface system ................................................... Strapped to skid on inside of crate

o Optional Roll of CheckMate Conveyor Wire Belt ........................ In a cardboard container strapped to skid

Figure 10 - Crated System


24/70


Aquastorm 200

o Cardboard Box Labeled "Documentation Package Enclosed"

- strapped to skid inside of crate Contains the following:

o System Documentation Package

o High Voltage Electrical Schematics

o Control Voltage Electrical Schematics

o System Installation Drawing

o Instruction Manual

o Bill Of Materials (BOM) Manual

o Assembly Drawings

o (2 Sets) Wire Belt Connecting Master Links

o (5) Drain Screens

o (12) Main Cabinet Leveling Feet

o (4) Optional Add-On Single Dryer Module Leveling Feet

o (Set of 59 SST Bolts, Flats & Lock washers) Optional Add-On Single

Dryer Module Interface Hardware

o (12) Pads for Leveling Feet

o (4) Pads for Optional Add-On Single Dryer Module Leveling Feet

o (2 Sets) Optional CheckMate Conveyor Connecting Master Links

Figure 11 - System Documentation Package


25/70


Aquastorm 200

SECTION 6 UNPACKING PROCEDURES(DOMESTIC SHIPMENTS ONLY)

Read this section in its entirety prior to

performing any unpacking procedures.

WARNING Heavy objects. Do not attempt tomove large assemblies without the useof a fork lift or other riggingequipment. Some large assemblies areextremely heavy and any attempt to

lift any assembly by hand will causepersonal injury.

5.1 INSTALLING THE SYSTEMLEVELING FEET

1 Wheel the Aquastorm 200 into placefor installation.

NOTE Do not remove any system

components from theircontainers prior to the

requirements of their

installation to prevent loss

of parts or installation

hardware.

2 Locate and open the cardboard containerlabeled "Documentation Package

Enclosed" then remove the system leveling

feet (quantity 12) from the container.

Figure 14 - Leveling Foot

Figure 13 - Leveling Feet in Documentation Package


26/70


Aquastorm 200

CAUTION To avoid damage to the equipment

and system drain fixtures, do notplace fork lift forks at the positionsindicated by the CAUTION labels.

Adjust the fork lift forks to their widestposition. The Aquastorm 200 frame

width is 152cm (59.9 inches) wide.Use fork extensions on forks if theforks do not extend at least seven (7)feet.

3 Using a two (2) ton (4,000 lb.) minimumcapacity fork lift, carefully position the

extended forks at their widest setting

under the frame of the Aquastorm 200.

Do not to place the forks at the CAUTION

points.

4 Once the fork lift is in place, carefullyraise the system off the floor high enough

to remove the wheels and install the 12

leveling feet obtained in step two (2).

A 1 1/2" adjustable or fixed wrench is

required for the removal of the hardware

securing the wheels and for the

installation of the leveling feet.

5 Install the leveling feet so they extendapproximately 12.7cm (five {5} inches)

from the base of the system frame. Be

consistent with each leveling foot.

6 Remove the 12 Pads for the leveling feetfrom the cardboard container labeled

"Documentation Package Enclosed". Place

the pads below where each of the levelingfeet will rest on the floor at the site of

installation.

7 Carefully and slowly lower the Aquastorm200 onto the pads at the site of

installation. Remove the fork lift.


27/70


Aquastorm 200

6.2 REMOVING THE SYSTEMPACKAGING MATERIALS

To ensure safe arrival to your facility, the

Aquastorm 200 and its components have been

carefully padded and secured. Remove the

packaging materials from the locations outlined

below.

CAUTION To prevent unnecessary damage to thecabinet's polypropylene surfaces, useextreme caution when cutting or

removing packaging materials so asnot to scratch or cut into thepolypropylene surfaces.

o Remove the plastic wrap from around the

perimeter of the system.

o Remove the Aquastorm 200 rear accesspanels to access the system tanks. Remove

the packaging tape securing the wash tank

lid, rinse tank lid, and optional chemical

isolation tank lid; reinstall the tank lids

and rear access panels.

Figure 16 - System with Protective Plastic Wrapping

Figure 17 - Tank Packaging

Remove the packagingfrom the tank area


28/70


Aquastorm 200

Proceed to Section 7 "System Leveling".

o Remove the packaging tape securing the

sound enclosure lid and tool kit door.

o Remove the packaging tape and foam

padding from the optional spray wand in

the sink.

Figure 18 - Exit End Packaging

Figure 19 - Optional Sink Packaging


29/70


Aquastorm 200

End Panel of Crate

SidePanelo

fCrate

End Panel of Crate

SidePanelof

Cr

Cut as indicated by the dotted lineafter adjusting the depth of the blade

Cut along opposite sidesand opposite ends

SECTION 7 CRATE DISMANTLING PROCEDURES(INTERNATIONAL SHIPMENTS ONLY)


performing any dismantling procedures to prevent

damage to the equipment.

WARNING Heavy objects. Do not attempt tomove large assemblies without the useof a fork lift or other rigging

equipment. Some large assemblies areextremely heavy and any attempt tolift any assembly by hand will causepersonal injury.

1 Transport the Aquastorm 200 system

crate to the general vicinity of installationusing a three (3) ton (6,000 lb.) minimum

capacity fork lift.

CAUTION Take caution not to scratch or damagethe cabinet's polypropylene surfaceswhile dismantling the crate.

2 Using a circular saw with a rip cut bladeadjust the blade depth to approximate ly

2cm (3/4"). Carefully cut one (1) end

panel of the crate as illustrated by the

dotted line in the photograph below

approximately 20cm (8") from the top of

the crate. Repeat this step for the

opposite end of the crate.

3 Now adjust the depth of the circular sawblade to maximum depth.

4 Cut along the length (long side) of one (1)side of the top edge of the crate as

illustrated by the dotted line in

photograph #2, approximately 20cm (8")

from the top of the crate.

5 Now make an additional cut using thecircular saw along the length (long side) of

the opposite side of the top edge of the

crate approximately 20cm (8") from the

top of the crate.

Figure 20 - Crate Dismantling

Figure 21 - Crate Dismantling


30/70


Aquastorm 200

6 The top of the crate should now be cut freefrom the crate. Carefully slide the top of

the crate off using several personnel or

with the aid of a fork lift. Do not drop the

trailing edge of the crate top, onto the top

of the system inside the crate.

7 Carefully remove any additional bracingfrom the inside of the top of the crate. Do

not damage the equipment.

8 Using pry bars and claw hammers removethe ends of the crate, then remove the

sides of the crate.

9 The entire Aquastorm 200 system hasbeen wrapped in moisture absorbent

plastic to prevent moisture damage to the

equipment during transit.

Remove the moisture absorbent plastic

from the system.

Figure 22 - Crate Opened


31/70


Aquastorm 200

10 Cut and remove the strapping securing allcardboard containers and optional

components secured to the system skid.

11 Carefully remove all components cut freein step 10 and place them in a safe place

close to the site of installation for use in

installation procedures that follow in this

manual.

NOTE Do NOT open any cardboard containers until

directed by the procedures

in this manual.

12 The Aquastorm 200 system is mountedon 2 x 8" planks with foam shock pads,

then bolted to a wooden skid.

1-8 x 3" Bolts installed in existing leveling

foot locations in eight (8) locations (4 in

front; 4 at the rear), secure 16 metal

shipping plates to the underside of the

system frame. 1/2-13 x 8" Bolts are then

inserted through mounting holes in the

skid, through the foam pads, through the

planks, then through the mounting holes

on the shipping plates, and retained with

jam nuts to secure the system in place on

the skid.


32/70


Aquastorm 200

Use a 3/4" socket wrench and ratchet to

remove the two (2) jam nuts from each of

the 16, 1/2-13 x 8" bolts from the

shipping plates.

CAUTION To avoid damage to the equipmentand system drain fixtures, do notplace fork lift forks at the positionsindicated by the CAUTION labels.

Adjust the fork lift forks to their widestposition. The Aquastorm 200 framewidth is 152cm (59.9 inches) wide.

Use fork extensions on forks if theforks do not extend at least seven (7)

feet.

13 Once all jam nuts have been removed fromthe 16 shipping plates, carefully position a

two (2) ton (4,000 lb.) minimum capacity

fork lift, with seven (7) foot (minimum)

fork extensions at their widest setting,

under the frame of the Aquastorm 200.

Do not position the forks at the

CAUTION points.

14 Once the fork lift is in place, carefullyraise the system off of the skid high

enough to remove the 16 shipping plates

and eight (8) 1-8 x 3" bolts securing them

to the system frame.

Use a 1 1/2"socket with ratchet to remove

the 1-8 x 3" bolts.

Proceed immediately to 6.1, Installing the

System Leveling Feet.


33/70


Aquastorm 200

7.1 INSTALLING THE SYSTEMLEVELING FEET

1 Locate and open the cardboard containerlabeled "Documentation Package

Enclosed". Remove the system leveling

feet (quantity 12) from the container.

2 While the Aquastorm 200. system isstill elevated above the skid, install the 12

leveling feet obtained in step one (1), six

(6) in front and six (6) at rear of system.

3 Install the leveling feet so they extendapproximately 12.7cm (five {5} inches)

from the base of the system frame. Beconsistent with each leveling foot.

Figure 29 - Leveling Foot

Figure 28 - Documentation Package


34/70

Aquastorm 200

28 Installation Setup

SECTION 8 INSTALLATION/SETUP


performing any installation procedure.

WARNING All procedures outlined in this sectionare to be performed in the order inwhich they are presented. Failure to

do so may result in damage to theequipment or personal injury.

8.1 POSITIONING THEAQUASTORM 200

Carefully make the final adjustments positioning

the Aquastorm 200 using a forklift so that the

system will be in place for operation. The machinefront and back sides should be facing correctly

for required operation.

o Using the fork lift, carefully position the

Aquasto rm 200 into pl ac e for

installation.

o Remove the 12 Pads for the leveling feet

from the cardboard container labeled

"Documentation Package Enclosed". Place

them below where each of the leveling feet

will rest on the floor at the si te ofinstallation.

o Carefully and slowly, lower the Aquastorm

200 onto the pads at the site of

installation; then, remove the fork lift.

Once the system is properly positioned proceed

to the Main Cabinet Leveling Procedure.


35/70

Aquastorm 200

Installation Setup 29

8.2 MAIN CABINETLEVELING PROCEDURE

1 On the "X" axis, place a level positionedon the underside corner of the Aquastorm

200 metal frame near the leveling foot.

2 Make the necessary height adjustments atthe base of the leveling foot hex head.

3 Turn the leveling foot hex head clockwiseto elevate the system or

counterclockwise to lower the system

until the distance between the base frame

of the cabinet and the floor is

approximately 10.16 cm (4 inches).

4 Repeat the above steps for all four (4)

corners of the system, front and rear.

5 On the "Y" axis, place the level positionedon the underside corner of the Aquastorm

200 frame near a leveling foot.

6 Make the necessary adjustments to theleveling feet to bring the system into

level.

7 Recheck the "X" axes to be sure theleveling at these points have not changed.

8 Repeat the above steps as necessary.

Base of Cabinet

Leveling FootHex Head

10.16 cm(4.0")

Twelve (12) Leveling Feet Locations Designated by this Symbol

Top View of Aquastorm 200

Y

X

Figure 31 - Leveling Foot Adjustment

Figure 32 -


36/70

Aquastorm 200


8.3 REMOVING THE SYSTEMPACKAGING MATERIALS

Now that the system is safely in place, the

packaging materials should be removed.

To ensure safe arrival to your facility, the

Aquastorm 200 has been carefully padded and

components secured by various means. Removethe packaging materials from the locations

outlined below.

CAUTION To prevent unnecessary damage to thecabinet's polypropylene surfaces, useextreme caution when cuttingstrapping or removing packagingmaterials so as not to scratch or cutinto the polypropylene surfaces.

o Remove the plastic wrap from around the

perimeter of the system.

Figure 33 - Removing the plastic wrap

Figure 34 - Removing the foam padding from the windows

o Remove the foam padding from the

windows and packaging tape from the

surfaces of the cabinet.

o If your system is configured with the

optional Inlet Conveyor, remove any

strapping and padding securing the

turnbuckles to the entrance end of the

cabinet. Carefully set the unsecured ends

of the turnbuckles on the floor until the

time of installation of the Inlet Conveyor.


37/70

Aquastorm 200


o Remove the Aqustorm 200 rear access

panels to access the system tanks. Remove

the packaging tape securing the wash tank

lid, rinse tank lid, and optional chemical

isolation tank lid; reinstall the tank lids

and rear access panels.

o Remove packaging tape securing the

sound enclosure lid and tool kit door.

o Remove the packaging tape and foam

padding from the optional spray wand in

the sink.

Fgure 35 - Tank Packaging

Remove the packagingfrom the tank area

Fgure 36 - Sound Enclosure and Tool Kit Door Packaging

Fgure 37 - Optional Sink Packaging


38/70

Aquastorm 200


8.4 INSTALLING THE DRAINSCREENS

The Aquastorm 200 has five (5) drain screens.

Two (2) in the prewash section; and one (1) in

each of the following tanks: wash, rinse, and

optional chemical isolation.

Refer to the illustration below for properinstallation of the drain screens.

1 Locate and remove the drain screens fromthe contents of the cardboard container

labeled "DOCUMENTATION

PACKAGE ENCLOSED".

2 Install the two (2) prewash drain screensfrom the front of the prewash section.

Open the front window, then remove the

prewash splash shield; install one (1)

drain screen over the prewash cascade

drain (the drain closest to the front of

the system), and one over the prewash

drain.

3 Go to the rear of the system and removethe rear access panels.

Remove the rear access panels starting

with the panel closest to the entrance

end.

4 Remove each of the tank covers from theirrespective tanks.

5 Install a drain screen in the bottom ofeach of the tanks.

6 Replace the tank covers on each of therespective tanks

Figure - 39 Drain Screen

Fgure 38 - Documentation Package

Install 2 Drain Screens in thePrewash section via the FrontWindow

Install a Drain Screen in the Wash,Rinse, and Optional Chemical Isolation

tanks from the rear of the system

Figure 40 - Prewash Drain Screen Location

Figure 41 - Tank Drain Screen Locations


39/70

Aquastorm 200


8.5 OPTIONAL SUMPPUMP INSTALLATION

Materials Required

610 cm (20 ') Maximum length of 11/

2" CPVC

drain pipe

Lengths of 1" facility drain pipe

Teflon

TapeCPVC Cement and Solvent

Tools Required

Channel lock pliers

Pipe wrench

NOTE Waste water d ischarge

solutions from the

Aquastorm 200 may be

regulated by local, county,

state or federal agencies.

Indiscriminate discharge is

not recommended.

Contact a local governing

agency for proper permits,

discharge requirements

and pretreatment

conditioning prior to

operating the Aquastorm

200.

Sump Pump

Refer to Figure 42 on page 34 labeled "Sump

Pump Installation" for steps 1 - 8 of this

procedure.

1 If your system has been configured withthe Optional Sump Pump, locate and

remove the assembly from the shipment

contents.

NOTE The Optional Sump Pump

assembly is configured

with the necessary

electrical connectors and

610 cm (20 ') of cable

Additional plumbing

required for site

installation is customersupplied; 1 1/2" CPVC

drain plumbing; 1" facility

drain plumbing. Be sure to

use Teflon tape on al

threaded plumbing

fittings. The Sump

assembly is designed to be

positioned at the exit end

of the Aquastorm 200

system.

2 Position the sump pump assembly at theexit end of the system, with the drain pipe

facing the exit end of the system.

3 Install a union or coupling (customersupplied) at the end of the 1

1/

2" drain

plumbing at the exit end of the Aquastorm

200 system.

4 Install the required length of 1 1/2" CPVC

drain pipe (not to exceed 610 cm {20 '})to the remaining end of the union or

coupling.

5 Connect the opposite end of the drain pipeinstalled in step 4 to the 1

1/2" NPTF

fitting on the sump.

6 Connect the 1.0" NPTF sump outlet tothe facility 1.0" (customer supplied) drain

or facility water treatment system.

7 Locate the cable from the sump pump withthe connector labeled PG27.

8 Plug the connector labeled PG27 into thereceptacle at the exit end of the

Aquastorm 200 labeled PG27.


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Aquastorm 200


ConnectSumpInlet(11/2"NPTF)

toAquastorm200's

standard11/2"NPTM,drain

attheexitendofthecabinet

11/2"CPVC

drainfromsystemtoSump

(CustomerSupplied)

ConnectSumpOutletto

1.0"NPTFFacilityDrain

(CustomerSuppliedplumbing)

SumpOutlet

1.0"NPTF

SumpS

ideView

ConnectPlug#PG27from

SumpintoSumpreceptacle

at

exitendofcabinetlabeled

PG27

Receptacle

InstallaUnion

orcouplingHere

Connector

Cable

SumpPumpInstallation

Figure4

2-


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Aquastorm 200


8.6 OPTIONAL TREATMENTINTERFACE INSTALLATION

Materials Required

457 cm (15 ') Maximum length of 11/2" CPVC

drain pipe

Lengths of 1" CPVC, schedule 80 facility

drain pipeLengths of 3/4" CPVC, schedule 80 fill pipe

Teflon Tape

Tools Required

Channel lock pliers

Pipe wrench

NOTE Waste water discharge

solutions from the

Aquastorm 200 may be

regulated by local, county,

state or federal agencies.

Indiscriminate discharge is

not recommended.

Contact a local governing

agency for proper permits,

discharge requirements

and pretreatment

conditioning prior to

operating the Aquastorm

200.

Treatment Interface System

Refer to Figure 43 on page 36 labeled "Treatment

Interface Installation" for steps 1 - 10 of this

procedure.

1 If your system has been configured withthe Optional Treatment Interface, locate

and remove the assembly from the

shipment contents.

NOTE The Optional Treatment

Interface assembly is

configured with the

necessary electrical

connectors and 610 cm

(20 ') of cable. Additional

plumbing required for

site installation is

customer supplied; 1 1/2"

CPVC drain plumbing;

1" faciltiy drain

plumbing, and 3/4" fill

plumbing. Be sure to use

Teflon tape on all

threaded plumbing

fittings. The Treatment

Interface assembly is

designed to be positioned

at the exit end of the

Aquastorm 200

system.

2 Position the treatment interface assemblyat the exit end of the system, with the

drain pipe facing the exit end of the

Aquastorm 200 system.

3 Install a union or coupling (customersupplied) at the end of the 1

1/

2" drain

plumbing at the exit end of the Aquastorm

200 system.

4 Install the required length of 11/2" CPVC

drain pipe (not to exceed 457 cm {15 '})

to the remaining end of the union or

coupling.

5 Connect the opposite end of the drain pipeinstalled in step 4 to the 1 1/2" NPTFfitting on the inlet side of the treatment

interface.

6 Connect the 1.0" NPTF treatmentinterface outlet to the optional CLS 1.0"

inlet (See CLS installation manual for

CLS fitting locations), using the customer

supplied 1.0" plumbing.

7 Connect the 3/4" fill line from the

Aquastorm 200 to the

3

/4" NPTF fittingon the treatment interface using the

customer suppplied3/

4" plumbing.

8 Connect the treatment interface 11/2

drain overflow to facility drain, or to the

optional sump pump's 11/

2" inlet side

drain plumbing. This connection is for

high level overflow only.


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Aquastorm 200


TreatmentTankSideView

ConnectPlug#PG26fromthe

Treatmentsystemintothereceptacle

atexitendofcabinetlabeledPG26

Receptacle

DrainOverflow

11/2"NPTF

InletFrom

AquastormDrain

11/2"NPTF

FillFrom

Aquastorm

3/4"NPTF

Outletto

CLS1"NPTF

Pump

OutlettoCLS1"NPTF

InletFrom

AquastormDrain

11/2"NPTF

DrainOverflow

11/2"N

PTF

System11/2"

DraintoOptional

SumporFacility

Drain

InstallCouplingHere

ConnectorCable

Figure43TreatmentInterfaceInstallation

9 Locate the cable from the treatmentinterface with the connector labeled

PG26.

10 Plug the PG26 connector into thereceptacle at the exit end of the

Aquastorm 200 labeled PG26.


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Aquastorm 200


8.7 OPTIONAL INLETCONVEYOR EXTENSIONINSTALLATION

Tools Required -

8 mm Box Wrench

13 mm Box Wrench

5 mm Allen Wrench

Refer to Figure 44 - Inlet Conveyor Installation

on page 38 for the assembly instructions which

follow.

1 Locate and remove the Adjustable InletConveyor Extension and mounting

hardware from the contents of the crate.

2 Using a 13 mm box wrench, remove thehardware, (2-9200-051-00-0, hex head

bolts, 2-9232-007-00-0, flat washers, 2-9233-005-00-0, lock washers) from

either end of the Idler Shaft Assembly to

allow removal of the idler shaft assembly

and spacers (525778-01) from the

conveyor extension.

NOTE Take caution not to lose

the Teflon spacers

(525778-01) at either

side of the inlet conveyor,

since they need to bereinstalled.

Do Not disassemble the

Idler Shaft Assembly.

3 Carefully, lift the inlet conveyor assembly.Install the end of the inlet conveyor, in

which the shaft assembly was removed,

into the entrance end mounting bracket

(3-0077-114-01-6). The bracket is

already installed on the Aquastorm 200cabinet. Utilize the vertical slotted

mounting hole for installation (refer to

Figure 43 - Inlet Conveyor Installation on

page 37).

4 Install the spacers (525778-01), quantityone (1) at either side of the inlet conveyor,

between the inlet conveyor and entrance

end mounting bracket.

5 While hold ing the spacers in placeposition the idler shaft assembly removed

in step 2. Align the mounting holes, then

install the hardware removed in step 2, (2

9200-051-00-0, hex head bolts, 2-9232

007-00-0, flat washers, 2-9233-005-00

0, lock washers) at either side of the inleconveyor.

Finger tighten the hex bolts at this time

so that angle adjustment may be made

DO NOT TIGHTEN SECURELY.

6 Locate the left (512779-01)and right(512778-01) threaded height adjustment

rods and turnbuckles (512780-01) that

were already installed on the system prior

to shipment.

Using a 5 mm Allen wrench and an 8 mm

box wrench, remove the shoulder screws

(2-9290-011-00-0) and hex nuts (2

9237-004-00-0) from the top ends of the

left hand threaded adjustment rods

(512779-01).

7 Align the holes in the ends of the left handthreaded adjustment rods (512779-01

with the mounting holes in the side panels

(3-0787-220-01-6) of the inlet conveyor.

8 Install the hardware removed in step 6through the threaded adjustment rods, to

the side panels of the inlet conveyor with

the heads of the shoulder bolts facing out

and the double hex nuts on the inside of

the inlet conveyor.

Tighten the hardware securely using a

5 mm Allen wrench and a 5 mm box

wrench.

9 Adjust the height of the Inlet ConveyorExtension to the required position by

turning the turnbuckles.

10 Once the inlet conveyor has been adjustedto the required operating position, use a

13 mm box wrench to tighten the

hardware which was finger tightened in

step 5.


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Aquastorm 200


2-9

200

-051

-00

-0

M8x

40SSTHex

Hea

dBo

lt

2

-9233

-005

-00

-0

M8SSTSp

litLoc

kWasher

2-9

232

-007

-00

-0

M8SSTFlatWasher

Idler

Sha

ftAssem

bly

3-0

077

-114

-01-6

Conveyor

Bracke

t

525778

-01

Spacer

2-9

290

-011

-00-0

8x

M6x

20Socke

t

Hea

dShou

lder

Bolt

2

-9237

-004

-00

-0

M5SSTHex

Nu

t

Idler

Sha

ftAssem

bly

512780

-01

Leftan

dRightTurn

buc

kles

512778

-01

RightThrea

de

d

He

ightAdjust

Ro

d

512779

-01

Left

Threa

de

d

He

igh

tAdjust

Ro

d

3-0

787

-220

-01

-6

Side

Plate

Figure44-

InletConveyorInstallation


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Aquastorm 200


8.8 OPTIONAL PHOTOCELLHOOK-UP

The optional photocell emitter and mounting

hardware are removed from the inlet conveyor

prior to shipment on crated shipments.

Locate the mounting hardware and photocell

components packaged at the entrance end of theAquastorm 200.

Align the mounting holes of the photocell

mounting bracket (p/n 523977-01) with the

slotted holes as depicted in the illustration below,

on the right hand side of the inlet conveyor, facing

the entrance end of the system.

Using the M 5 hardware illustrated in the diagram

Detail "A"

Detail "A"

M 5 Pan Head Bolt2-9210-030-00-0 ( QTY 2)

M 5 Lock Washer2-9233-003-00-0 (QTY 2)

M 5 Flat Washer2-9232-022-00-0 (QTY 4)

M 5 Hex Nut2-9237-004-00-0 (QTY 2)

Photocell Mounting Bracket523977-01

below, insert the pan head bolts with flat washers

through the slotted holes on the inside of the

inlet conveyor through the mounting holes of the

photocell mounting bracket.

Install the M 5 lock (2-9233-003-00-0)and M 5

flat (2-9232-022-00-0) washers on the back side

of the bolt (2-9210-030-00-0) , then secure withthe M 5 hex nut (2-9237-004-00-0).

NOTE Befo re opera ti ng the

photocell, perform the

Photocell Alignmen

procedure on page 2-14 of

the Instruction Manual.

Figure 45 - Photocell Mounting


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Aquastorm 200


8.9 BOLT ON SOUNDENCLOSURE INSTALLATION(Crated Shipments Only)

The sound enclosure is designed for removal prior

to shipping for those shipments which are to be

crated.

For shipments that are received crated, performthis installation procedure.

Refer to Figure 63 below for the installation of

the sound enclosure.

1 The Sound Enclosure is to be installedusing M6 metric hardware. Locate the 24

sets of M6 hardware inside the box labeled

"Documentation Package".

CAUTION Heavy Object - The exit end soundenclosure is heavy. Arrange for three

(3) or four (4) personnel to lift it intoposition, or use the appropriaterigging equipment to position the

sound enclosure for installation.

2 Position the sound enclosure at the exitend of the Aquastorm 200 system

cabinet as illustrated in Figure 63.

3 Install two (2) M6 x 40 hex head bolts (2-9200-035-00-0) with M6 flat washers (2-

9232-023-00-0) into the two (2) upper

most corner mounting holes, from the

inside of the sound enclosure.

Use these two (2) holes to align the soundenclosure to the Aquastorm's exit end

bulkhead mounting holes.M6 Flat Washer

2-9232-023-00-0

M6 x 40 Hex Head Bolt2-9200-035-00-0

Bolt Thru Exit Bulkhead andExit Enclosure (24 sets of hardware)

M6 Flat Washer2-9232-023-00-0

M6 Hex Nut2-9237-005-00-0

M6 Lockwasher2-9233-004-00-0

Sound EnclosureBulkhead shownBlown out fromAssembly to showMounting hole Locations

Sound Enclosure

Close-Up Cut-Away View ofMounting Hardware Configuration

Sound EnclosureBulkhead

Aquastorm 200Exit End Bulkhead

Figure 63 - Sound Enclosure Installation


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Aquastorm 200


4 Secure the two (2) sets of hardwareinstalled in step 3, by installing an M6 flat

washer (2-9232-023-00-0), M6 lock

washer (2-9233-004-00-0), and an M6

hex nut (2-9237-005-00-0) on the bolts

from the inside of the Aquastorm's exit

end of the cabinet. DO NOT tighten

completely until all additional mounting

hardware has been completely installed.

5 Install all remaining, 22 sets, of hardwarein the mounting holes illustrated in Figure

63 on page 40, then tighten securely.


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Aquastorm 200


8.10 CONVEYOR WIRE BELTINSTALLATION(CRATED SHIPMENTS ONLY)

When the Aquastorm 200 is shipped crated,

the Optional Inlet conveyor extension and the

conveyor wire belt are removed for shipment.

Perform this procedure if your system was

received as a crated shipment with the Optional

Inlet conveyor extension.

NOTE If your system is not

configured with the

Optional Inlet ConveyorExtension, the conveyor

wire belt is not removed

from the system for

shipment, therefore it is

not necessary to perform

this procedure.

1 Locate and remove the roll of ConveyorWire Belt from the contents of the

shipment.

2 Bring the roll of wire belt to the exit endof the Aquastorm 200.

3 Arrange the wire belt so the Closed End of

the Hook Loops are facing towards the

EXIT end of the Aquastorm 200.

Open Side of LoopFacing Toward

Entrance End

Closed Loop SideToward Exit End

Feeding the Wire Belt

Entrance End Exit End

Feed the Wire Belt from the top of the cotoward the exit end of the system, then athe underside of the conveyor, toward theend of the Optional Inlet Conveyor assemb

Figure 46 - Wire Belt Installation


49/70

Aquastorm 200


Feeding the Wire Belt

Feed the Wire Belt from the top of the conveyortoward the exit end of the system, then around

the underside of the conveyor, toward the entranceend of the optional Inlet Conveyor assembly.

Feed over Top

Pull from Bottom

4 Manually feed the wire belt from theentrance end of the cabinet through the

TOP PORTION of the conveyor first.

5 Pull the wire belt all the way through thesystem to the exit end of the conveyor.

Pull the wire belt through the system by

reaching inside the window port of eachstage and pulling the wire belt through.

6 Bring the wire belt around to the bottomof the exit end of the conveyor, so that it

hangs approximately 15.24cm (6 inches)

over the end.

7 Go to the entrance end at the OptionalInlet Conveyor and feed the remaining

portion of the wire belt through the

system, leaving enough wire belt to extend

to the middle of the inlet conveyor.

Assist pulling the wire belt from the exit

end of the conveyor, and by reaching

inside the window port of each stage an

Aquastorm 200 Installation Manual

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