Aquastorm 200 Installation Manual

Aquastorm 200
Aquastorm 200
Aqueous Cleaning System
Installation Manual
Manual Part Number 2-9316-646-00-0 Text Part Number 2-9316-645-00-0
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.
i
Aquastorm 200
ELECTROVERT
Electrovert U.S.A. Corp. P Box 709, Highway 5 South .O. Camdenton, MO 65020-0709
The Serial Tag information is to be filled in by the user for T echnical Support purposes. Please have this information available when contacting Technical Support or when placing parts orders.
ii
Aquastorm 200
INTRODUCTION
Congratulations on your purchase of an Aquastorm 200 Aqueous Cleaning System. The Aquastorm 200 is a powerful, efficient aqueous cleaner designed for the removal of contaminated fluids and particles left behind from wave soldering and/ or reflow processes on complex surface mount and mixed technology PWAs. Each section of the Aquastorm 200 has been carefully integrated and balanced to achieve the best cleaning and drying capability for its size and cost, available in the industry. The purpose of this manual is to help obtain the greatest possible return on your investment. It is suggested that new operators study the applicable sections of this manual thoroughly before operating the equipment. It is further suggested that the manual be used as a reference by maintenance personnel and as a text for training of new maintenance personnel. This manual includes operating instructions for this equipment available at the time this manual was approved for printing. Electrovert reserves the right to make changes in design and specifications and/or make additions to or improvements in the product without imposing any obligations upon itself to install them on previously manufactured products.
Electrovert Sales and Service Offices

Electrovert Main Offices
Product & Technology Center Electrovert USA Corp. 1111 W. North Carrier Parkway Grand Prairie, TX 75050 Fax: 972-606-1700 Tel: 972-606-1900 Technical Service Support Group & Customer Service Parts Department Electrovert USA Corp. P Box 709 .O. Camdenton, MO 65020 Fax: 573-346-6878 Tel: 573-346-3341 Educational Services & Customer Support Center 580-A Tollgate Road Elgin, IL 60123 Fax: 847-289-3797 Tel: 847-695-5750
Regional Service Centers

North East Regional Service Center 472 Amherst St. Suite 6 Nashua, NH 03063 Fax: 603-880-8757 Tel: 603-883-2488 South East Regional Service Center 200 Technology Dr. Alpharetta, GA 30005 Fax: 770-442-1987 Tel: 770-475-6100 North Central Regional Service Center 580-A Tollgate Road Elgin, IL 60123 Fax: 847-289-3797 Tel: 847-695-5750 North West Regional Service Center 2968 Scott Blvd. Santa Clara, CA 95054 Fax: 408-727-0672 Tel: 408-727-4650 South West Regional Service Center 1111 W. North Carrier Parkway Grand Prairie, TX 75050 Fax: 972-606-1700 Tel: 972-606-1900
International Service Centers

Northern Europe & U.K. Electrovert U.K. Ltd. The Technology Centre Unit 1, Pincents Kiln Industrial Park Pincents Kiln Calcot, Reading Berks., U.K. RG31 7SO Fax: 44 11-8-930-1401 Tel: 44 11-8-930-1400 Electrovert Singapore 10 Kian Teck Crescent Singapore 628876 Fax: 65-861-7337 Tel: 65-861-1661 Japan Electrovert-Seitec Co., Ltd. 1538 Kanoya-cho Hachioji City, Tokyo 193 JAPAN Fax: 81-426-23-8350 Tel: 81-426-23-7722 Northern Europe Speedline Technologies S.A.R.L. 65 Avenue du General De Gaulle Immeuble le Promethee 77420 Champs-Sur Marne, France Fax: 33 160-05-6129 Tel: 33 160-06-8181 Central Europe Speedline Technologies, Gmbh Daimlerstrasse 1E D-63303 Dreieich, Germany Fax: 49 6103-832119 Tel: 49 6103-8320 Speedline Technologies Italy Via Liguria 2/28 I-20068 Peschiera Borromeo (MI) Italy Fax:39- 2 - 5530.8468 Tel: 39- 2 - 5530.8339
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Aquastorm 200
TABLE OF CONTENTS
SECTION 1
1.1 1.2 SECTION 2 2.1
GENERAL ................................................................................................................................... 1
HAZARDS ........................................................................................................................................................... 1 SAFETY PRECAUTIONS ....................................................................................................................................... 3 Technical Data ........................................................................................................................................... Facility Requirements ........................................................................................................................................... Water Requirements ..................................................................................................................................... Final Rinse ................................................................................................................................................... Fill .............................................................................................................................................................. System Drain ................................................................................................................................................ Exhaust Requirements ................................................................................................................................... Electrical Requirements ................................................................................................................................. Reference Schematics ................................................................................................................................... Power .......................................................................................................................................................... Capacities ................................................................................................................................................... Specifications ............................................................................................................................................... Dimensions ......................................................................................................................................................... Installation Preparation ............................................................................................................................ Receiving Instructions ......................................................................................................................................... Installation Planning .......................................................................................................................................... System Footprint Drawing ................................................................................................................................... Installation Check List ........................................................................................................................................ Equipment / Tools Required ...................................................................................................................... Protective Clothing ............................................................................................................................................ Tools and Materials ........................................................................................................................................... Expendable Items .............................................................................................................................................. Rigging Equipment ............................................................................................................................................ Maintenance ..................................................................................................................................................... Shipping Arrangement ............................................................................................................................. Shipping Weights and Dimensions ...................................................................................................................... Domestic Shipment Dimensions .......................................................................................................................... Packaging Configuration .................................................................................................................................... Domestic Shipments Packaging Arrangement ....................................................................................................... International Shipments Packaging Arrangement .................................................................................................. 5 5 5 5 5 5 5 6 6 6 7 7 8
2.2 SECTION 3 3.1 3.2 3.3 SECTION 4 4.1 4.2 4.3 4.4 4.5 SECTION 5 5.1 5.2
11 11 11 12 13 14 14 14 14 14 14 15 15 15 16 16 17
SECTION 6 6.1 6.2 SECTION 7 7.1 SECTION 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13
Unpacking Procedures (Domestic Shipments Only) .................................................................................... 19 Installing the System Leveling Feet ....................................................................................................................... 19 Removing the system Packaging Materials ........................................................................................................... 21 Crate Dismantling Procedures (International Shipments Only) ................................................................... 23 Installing the System Leveling Feet ....................................................................................................................... 27 Installation / Set-Up ................................................................................................................................. 28 Positioning the Aquastorm 200 ............................................................................................................................................................................................. 28 Main Cabinet Leveling Procedure ....................................................................................................................... 29 Removing the System Packaging Materials ........................................................................................................... 30 Installing the Drain Screens ................................................................................................................................ 32 Optional Sump Pump Installation ....................................................................................................................... 33 Optional Treatment Interface Installation ............................................................................................................. 35 Optional Inlet Conveyor Installation .................................................................................................................... 37 Optional Photocell Hook-Up .............................................................................................................................. 39 Bolt On Sound Enclosure Installation (Crated Shipments Only) .............................................................................. 40 Conveyor Wire Belt Installation (Crated Shipments Only) ...................................................................................... 42 Wire Belt Splicing Instructions ............................................................................................................................. 45 Pump Drain Plug Installation .............................................................................................................................. 50 Facility Connections .......................................................................................................................................... 51 Facility Water Hook-Up ..................................................................................................................................... 51 Rinse Hose ....................................................................................................................................................... 52 Facility Exhaust Hook-Up ................................................................................................................................... 53 Facility Power Connection .................................................................................................................................. 54
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Aquastorm 200
8.14
8.15
System Electrical Check ...................................................................................................................................... Main Power ...................................................................................................................................................... Secondary Voltage ............................................................................................................................................ Motor Rotation Check ........................................................................................................................................ Other ...............................................................................................................................................................
57 57 58 61 64
Aquastorm 200
LIST OF FIGURES
SECTION 2
Figure 1 - Cabinet Dimensions .................................................................................................... 8 Figure 2 - Inlet Conveyor Dimension ........................................................................................... 8 Figure 3 - Treatment Interface Dimensions.................................................................................... 9 Figure 4 - Sump Pump Dimensions .............................................................................................. 9
SECTION 3
Figure 7 - Aquastorm 200 System Footprint Layout Drawing ..................................................... 12

SECTION 5
Figure 8 - Domestic Packaging Arrangement .............................................................................. Figure 9 - Documentation Package ........................................................................................... Figure 10 - Crated System ........................................................................................................ Figure 11 - System Documentation Package ...............................................................................
SECTION 6
16 16 17 18
Figure 13 - Leveling Feet in Documentation Package .................................................................. Figure 14 - Leveling Foot .......................................................................................................... Figure 16 - System with Protective Plastic Wrapping .................................................................... Figure 17 - Tank Packaging ...................................................................................................... Figure 18 - Exit End Packaging .................................................................................................. Figure 19 - Optional Sink Packaging .........................................................................................
SECTION 7
19 19 21 21 22 22
Figure 20 - Crate Dismantling ................................................................................................... Figure 21 - Crate Dismantling ................................................................................................... Figure 22 - Crate Opened ........................................................................................................ Figure 28 - Documentation Package ......................................................................................... Figure 29 - Leveling Foot ..........................................................................................................
SECTION 8
23 23 24 27 27
Figure 31 - Leveling Foot Adjustment ......................................................................................... Figure 32 - Twelve Leveling Feet Locations ................................................................................. Figure 33 - Removing the Plastic Wrap ...................................................................................... Figure 34 - Removing the foam padding from the windows ......................................................... Figure 35 - Tank Packaging ...................................................................................................... Figure 36 - Sound Enclosure and Tool Kit Door Packaging .......................................................... Figure 37 - Optional Sink Packaging ......................................................................................... Figure 38 - Documentation Package ......................................................................................... Figure 39 - Drain Screen .......................................................................................................... Figure 40 - Prewash Drain Screen Location ................................................................................ Figure 41 - Tank Drain Screen Locations .................................................................................... Figure 42 - Sump Pump Installation ........................................................................................... Figure 43 - Treatment Interface Installation ................................................................................. Figure 44 - Inlet Conveyor Installation ....................................................................................... Figure 45 - Photocell Mounting ................................................................................................. Figure 63 - Sound Enclosure Installation ....................................................................................
vi
29 29 30 30 31 31 31 32 32 32 32 34 36 38 39 40
Aquastorm 200
Figure 46 - Wire Belt Installation ............................................................................................... 42 Figure 47 - Feeding the Wire Belt .............................................................................................. 43 Figure 48 - Wire Belt Master Links ............................................................................................. 44 Wire Belt Splicing Photographs ................................................................................................ 45 - 47 Photograph 1 .......................................................................................................................... 45 Photograph 2 .......................................................................................................................... 45 Photograph 3 .......................................................................................................................... 46 Photograph 4 .......................................................................................................................... 46 Photograph 5 .......................................................................................................................... 47 Photograph 6 .......................................................................................................................... 47 Photograph 7 .......................................................................................................................... 47 Wire Belt Company of America Illustrations ............................................................................... 48 - 49 Illustration 1 - 3 ....................................................................................................................... 48 Illustration 4 - 7 ....................................................................................................................... 49 Figure 50 - Facility Exhaust Connections .................................................................................... 53 Figure 51 - Ground Connections .............................................................................................. 54 Figure 52 - Serial Tag, Conduit Connector, and Incoming Power Locations ................................... 55 Figure 53 - Main Power Connections ......................................................................................... 56 Figure 54 - System Serial Tag .................................................................................................... 57 Figure 55 - Secondary Voltage Testing ....................................................................................... 58 Figure 56 - Clamp Ammeter ..................................................................................................... 59 Figure 57 - High Voltage Panel Layout/ Test Points ...................................................................... 60 Figure 58 - Control Panel Quick Reference ................................................................................ 61 Figure 59 - Rear View of Blower Location ................................................................................... 62 Figure 60 - Blower Rotation Tag ................................................................................................ 62 Figure 61 - Control Panel Quick Reference ................................................................................ 62 Figure 62 - Power Phasing ........................................................................................................ 63
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Aquastorm 200
SECTION 1
1.1 HAZARDS
GENERAL
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 nature throughout the context of this manual. When performing tests using ammeters, volt meters or ohm meters, electrical shock hazard is present. These procedures must be performed only by an authorized electrician, electrical engineer or service technician familiar with testing live voltage.
DANGER
High Voltage: Installation of this equipment involves exposure to High Voltage. High voltage can shock, burn or cause death. Use extreme caution when performing voltage and amperage tests on live voltage. These procedures must be performed only by an authorized electrician, electrical engineer 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. Appropriate clothing and safety articles must be worn when using descaler and saponifier solutions. Skin or eye irritation will occur if not handled properly.
General
Aquastorm 200
WARNING
Hot Surfaces/Burn Hazard: During normal operation this equipment and some of its components operate at temperatures up to 60-71 oC (140-160 oF). The operator must use extreme caution and wear the recommended 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 to cool before handling whenever possible.
WARNING
Heavy Objects: When attempting to move heavy equipment or components, it is imperative to use the proper rigging equipment. Do not attempt to move skids or large assemblies without the use of a fork lift or other rigging equipment. Hand lifting will cause serious personal injury.
General
Aquastorm 200
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 71o C (160o 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) for the specific use, handling, and safety procedures for their applications.
General
Aquastorm 200
DANGER
Danger notices are used in this manual to warn the operator that DEATH may result if a procedure is omitted or improperly performed.
WARNING
Warning notices are used in this manual to emphasize hazardous voltages, high currents, high temperatures or other conditions that could cause personal injury.
CAUTION
Caution notices are used to call attention to a situation that could cause damage to the equipment.
General
Aquastorm 200
SECTION 2
2.1
TECHNICAL DATA
FACILITY REQUIREMENTS
Water Requirements NOTE The Fill and Final Rinse water supplies must be separate. The immersion heaters in the Recirculating Wash and Rinse tanks will heat incoming tap or treated water after an initial waiting period. Electrovert recommends supplying heated water 60 - 71o C (140 - 160o F) to the Recirculating Wash, Rinse, and optional chemical isolation tanks in order to maintain operating temperatures. Exhaust Requirements NOTE The following exhaust specifications 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. 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 blower requirements and ventilation hook-up.
Recommended venting material - 25.4 cm (10 ") diameter, seamless stainless steel or PVC air duct. Total system requires 68 M 3/min. @ 2.5 cm (2400 SCFM @ 1") H2O static pressure. Port #1 - 34 M 3/min. @ 2.5 cm (1200 SCFM @ 1.0") H2O static pressure. Port #2 - 34 M 3/min. @ 2.5 cm (1200 SCFM @ 1.0" ) H2O static pressure.
NOTE
NOTE
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
Technical Data
Aquastorm 200
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
NOTE
Reference Schematics
VOLTAGE 460V, 60Hz 220V, 60Hz 380V, 50Hz Panel Layout DRAWING # 8-1679-006-01-2 8-1679-005-01-2 8-1679-003-01-2 8-1679-004-01-2
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.
Power
Standard Configuration Voltage 220 VAC, 60 Hz 380 VAC, 50 Hz 460 VAC, 60 Hz F.L.A. 264 152 126 Total KVA 100.6 100.6 100.6 Recommended Service 325 200 150
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 Chemical Isolation blower and a tank immersion heater.
F.L.A. 315 182 150 Total KVA 120 120 120 Recommended Service 400 250 200
Voltage 220 VAC, 60 Hz 380 VAC, 50 Hz 460 VAC, 60 Hz
Pump and Blower Upgrade Level 2 Configuration
NOTE
This configuration upgrades the Wash and Rinse pumps to 10 HP; adds an IR Dryer to Dryer #2; the blower in Dryer #1 is upgraded to 15 HP; adds the Enhanced Chemical Isolation tank immersion heater.
F.L.A. 360 206 171 Total KVA 136 136 136 Recommended Service 450 275 225
Voltage 220 VAC, 60 Hz 380 VAC, 50 Hz 460 VAC, 60 Hz
Technical Data
Aquastorm 200
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 Total (2) 16 KW Heaters; 32 KW
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 Total (2) 16 KW Heaters; 32 KW
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 Option 2 - 15 HP, 3 Ph, 460 VAC, 875 CFM Turbine Blower Dryer #2 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 Optional Radiant Heater (2) 1800 Watt 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.)
Technical Data
Aquastorm 200
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")
Optional Status Tower - 58.9cm (23.2") from top of Main Cabinet Exhaust Vent - 5 cm (2.0") from the top of the Main Cabinet
5 cm
(2.0") 691 cm (272") 5 cm (2.0"
128 cm (50.24")
10.16 cm 154 cm (60.51")
(4.0")
600 cm (236.38")
Figure 1 - Cabinet Dimensions
Leveling Feet - 10.16 cm (4") Optional Inlet Conveyor 85.8cm (33.8")

91.44 cm (36.0")
Figure 2 - Inlet Conveyor Dimension 8 Technical Data
Aquastorm 200
Optional Treatment Interface system 133.6 cm (52.1") L x 68.3 cm (26.7") W x 81.62 cm (32.13") H
81.62 cm (32.13") 68.3 cm (26.7")
133.6 cm (52.1") Figure 3 - Treatment Interface Dimensions
Optional Sump Pump 61.6 cm (24") L x 42.5 cm (16.6") W x 61.8 cm (24.1") H
Figure 4 - Sump Pump Dimensions
Technical Data
Aquastorm 200
SECTION 3
3.1
INSTALLATION PREPARATION
3.2 INSTALLATION PLANNING
Allocate sufficient 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 functions require 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, level 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.
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 of claim 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.
Installation Preparation
11
4488 (175.0) 4270 (166.5) 4030 (157.2) 445 (17.4) 610 (23.8) Fill Line To Rinse Final Rinse Line 445 (17.4) 445 (17.4) 610 (23.8) 305 (11.9) 4390 (171.2) Blower Slide Access Area
4584 (178.8)
5359 (209.0)
6743/ 6681 (265.5/ 263.0)
137/ 75 (5.4/ 3.0) 632 (24.6) Ext. Feed C.I. Line (Optional) 1575 (61.4) Standard Inlet Conveyor Split Fill Line To Wash (Optional)
2985 1903 (116.5) (74.2) Blower Slide Access Area 1518 (59.2)
Std. Drain
787 1105 (30.7) (43.1) 1375 (53.6)
12
Control Panel 1175 (45.8) 1095 (42.7) Electrical Cabinet Access Area Electrical Cabinet Access Area 7540 (294.1) 7478 (291.6) 457 (17.8) Conveyor Extension (Optional) 5944 (231.8) 194 (7.6) 548 (21.4) 267 (10.5) Exhaaust Port (2 PL) 1327 (51.8) 842 (32.8) 1185 (46.2) Prewash 559 (22.0) Wash 1219 (48.0) Chemical Iso. 889 (35.0) Rinse 1219 (48.0) 102/ 127 (4.0/ 5.0) Adjustable Legs 248 (9.7) 1059 (41.3) 1054 (41.1) 1156 (45.1) 6004 (234.2) Frame
CLS Drain (Optional) 831 (32.4) Elec. Conn. 3" Conduit
Aquastorm 200
1820 (71.0)
60 (2.3)
Light Status Tower (Optional)
508 (19.8)
589 (23.0)
Exit
1276 (49.8)
Final Rinse 432 (17.0)
Dryer #1 756 (29.8)
Dryer #2 752 (29.6)
Disconnect Elec. Conn. 3" Conduit 842 (32.8)
20 (.8)
105 (4.1)
1060 (41.3)
1056 (41.2)
1238 (48.3)
43 (1.7) System Drain
135 (5.3)
1537 (59.9) Frame
Inlet Connections
Figure 7 - Aquastorm 200 System Footprint Layout Drawing
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
Check For:
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:
SHIPPING DAMAGE
Check for damage to system:
If damage is found, please describe:
SYSTEM LEVELING
Level "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
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 with Optional 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
COMPLETE UTILITY CONNECTIONS

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
Optional Dual Add-On Dryer Module Bolt on Sound Enclosure Exit End Conveyor Drive Assembly Pump Drain Plugs NOTES:
13
Aquastorm 200
SECTION 4
4.1
EQUIPMENT/ TOOLS REQUIRED

4.4 RIGGING EQUIPMENT
(Domestic Shipments) 2 Ton Capacity (minimum) Fork Lift (International Shipments) 3 Ton Capacity (minimum) Fork Lift
PROTECTIVE CLOTHING
ANSI (American National Standard Institute) Approved Safety Glasses Steel Toe Safety Shoes Acid Resistant Smock Long-Sleeved Garment Heat Protective Gloves
4.5
MAINTENANCE
Heavy Duty Hose (3/4") Nozzle and Storage Reel
4.2
TOOLS AND MATERIALS

Flat Blade Screwdriver Phillips Head Screwdriver Channel Lock Pliers Pipe Wrenches T eflon 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 Cleaner Saponifier Scale Stripper Defoamer
14
Aquastorm 200
SECTION 5
SHIPPING ARRANGEMENT
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.
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 the skidded system to the site of installation.
NOTE
All weights and dimensions are approximated figures and are to be used as reference only.
Domestic Shipment Dimensions

Cabinet Length Cabinet Width Cabinet Height 684 cm (269") 158 cm (62") 145 cm (57")
WARNING
Move the Aquastorm 200 system crate using a fork lift. This equipment is extremely heavy and attempting to hand lift will result in personal injury. Transport the Aquastorm 200 system crate to the site of installation using a fork lift.
CAUTION
Do Not open crates prior to moving them to their final site of installation or damage may occur.
5.1
SHIPPING WEIGHTS AND DIMENSIONS

NOTE This manual makes reference to both standard and optional configurations. Disregard options which do not apply to your system configuration.
15
Aquastorm 200
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:
Domestic Shipments Packaging Arrangement

o o o o o o Main Cabinet ......................................................................................................................On Wheels Optional Add-On Single Dryer Module .................................................................................. On Wheels Optional Add-On Dual Dryer Module ....................................................................................On Wheels Optional Sump Pump .......................................................................................On Van wrapped in pads Optional Sump Pump Plumbing, rubber unions and Hose Clamps ....................................... Loose on Van Optional Treatment Interface system ................................................................................. Loose on Van
Figure 8- Domestic Packaging Arrangement
o o o o o o o o o o o o o o o o
Cardboard Box Labeled "Documentation Package Enclosed System Documentation Package High Voltage Electrical Schematics Control Voltage Electrical Schematics System Installation Drawing Instruction Manual Bill Of Materials (BOM) Manual Assembly Drawings (2 Sets) Wire Belt Connecting Master Links (5) Drain Screens (12) Main Cabinet Leveling Feet (4) Optional Single Add-On Dryer Module Leveling Feet Set of Optional Single Add-On Dryer Module Interface Hardware (12) Pads for Leveling Feet (4) Pads for Optional Single Add-On Dryer Module Leveling Feet (2 Sets) Optional CheckMate Conveyor Connecting Master Links
16 Installation Preparation
- Contains the following:
Figure 9 - Documentation Package
Aquastorm 200
International Shipments Packaging Arrangement

o o o o o o o o o o Main Cabinet ................................................................................................. Bolted to skid and crated Optional Add-On Single Dryer Module ............................................................. Bolted to skid and crated Optional Add-On Dual Dryer Module ............................................................... Bolted to skid and crated Roll of Conveyor Wire Belt ....................................................... In a cardboard container strapped to skid Opitonal Adjustable Inlet Conveyor Extension ............................ In a cardboard container strapped to skid Exit End Sound Enclosure ................................................................ Strapped to Skid on inside of crate Exit End Conveyor Extension ............................................................. Strapped to skid on inside of crate Optional Sump Pump system .............................................................. Strapped to skid on inside of crate Optional Treatment Interface system ................................................... Strapped to skid on inside of crate Optional Roll of CheckMate Conveyor Wire Belt ........................ In a cardboard container strapped to skid
Figure 10 - Crated System
17
Aquastorm 200
Cardboard Box Labeled "Documentation Package Enclosed" - strapped to skid inside of crate Contains the following: System Documentation Package High Voltage Electrical Schematics Control Voltage Electrical Schematics System Installation Drawing Instruction Manual Bill Of Materials (BOM) Manual Assembly Drawings (2 Sets) Wire Belt Connecting Master Links (5) Drain Screens (12) Main Cabinet Leveling Feet (4) Optional Add-On Single Dryer Module Leveling Feet (Set of 59 SST Bolts, Flats & Lock washers) Optional Add-On Single Dryer Module Interface Hardware (12) Pads for Leveling Feet (4) Pads for Optional Add-On Single Dryer Module Leveling Feet (2 Sets) Optional CheckMate Conveyor Connecting Master Links
o o o o o o o o o o o o o o o
Figure 11 - System Documentation Package
18
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 to move large assemblies without the use of a fork lift or other rigging equipment. Some large assemblies are extremely heavy and any attempt to lift any assembly by hand will cause personal injury.
5.1
INSTALLING THE SYSTEM LEVELING FEET

1 Wheel the Aquastorm 200 into place for installation.
NOTE
Do not remove any system components from their containers prior to the requirements of their installation to prevent loss of parts or installation hardware.
Figure 13 - Leveling Feet in Documentation Package
Locate and open the cardboard container labeled "Documentation Package Enclosed" then remove the system leveling feet (quantity 12) from the container.
Figure 14 - Leveling Foot Installation Preparation 19
Aquastorm 200
5 CAUTION To avoid damage to the equipment and system drain fixtures, do not place fork lift forks at the positions indicated by the CAUTION labels. Adjust the fork lift forks to their widest position. The Aquastorm 200 frame width is 152cm (59.9 inches) wide. Use fork extensions on forks if the forks do not extend at least seven (7) feet.
Install the leveling feet so they extend approximately 12.7cm (five {5} inches) from the base of the system frame. Be consistent with each leveling foot. Remove the 12 Pads for the leveling feet from the cardboard container labeled "Documentation Package Enclosed". Place the pads below where each of the leveling feet will rest on the floor at the site of installation. Carefully and slowly lower the Aquastorm 200 onto the pads at the site of installation. Remove the fork lift.
7 3 Using a two (2) ton (4,000 lb.) minimum capacity 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. Once the fork lift is in place, carefully raise 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.
20
Aquastorm 200
6.2
REMOVING THE SYSTEM PACKAGING 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 the cabinet's polypropylene surfaces, use extreme caution when cutting or removing packaging materials so as not to scratch or cut into the polypropylene surfaces.
Remove the plastic wrap from around the perimeter of the system.
Figure 16 - System with Protective Plastic Wrapping
Remove the Aquastorm 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.
Remove the packaging from the tank area
Figure 17 - Tank Packaging Installation Preparation 21
Aquastorm 200
Remove the packaging tape securing the sound enclosure lid and tool kit door.
Figure 18 - Exit End Packaging
Remove the packaging tape and foam padding from the optional spray wand in the sink.
Figure 19 - Optional Sink Packaging
Proceed to Section 7 "System Leveling".
22
Aquastorm 200
SECTION 7
CRATE DISMANTLING PROCEDURES

(INTERNATIONAL SHIPMENTS ONLY)
Read this section in its entirety prior to performing any dismantling procedures to prevent damage to the equipment.
WARNING
Heavy objects. Do not attempt to move large assemblies without the use of a fork lift or other rigging equipment. Some large assemblies are extremely heavy and any attempt to lift any assembly by hand will cause personal injury.
Using a circular saw with a rip cut blade, adjust the blade depth to approximately 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.
Cut as indicated by the dotted line after adjusting the depth of the blade
Transport the Aquastorm 200 system crate to the general vicinity of installation using a three (3) ton (6,000 lb.) minimum capacity fork lift.
End Panel of Crate
e Sid
e rat fC lo ne Pa
CAUTION
Take caution not to scratch or damage the cabinet's polypropylene surfaces while dismantling the crate.
Cut along opposite sides and opposite ends
Figure 21 - Crate Dismantling
Now adjust the depth of the circular saw blade to maximum depth. 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. Now make an additional cut using the circular 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.
e Sid
End Panel of Crate
e rat fC lo ne Pa
Figure 20 - Crate Dismantling Installation Preparation 23
Aquastorm 200
The top of the crate should now be cut free from 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.
Carefully remove any additional bracing from the inside of the top of the crate. Do not damage the equipment. Using pry bars and claw hammers remove the ends of the crate, then remove the sides of the crate. The entire Aquastorm 200 system has been 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
24
Aquastorm 200
10
Cut and remove the strapping securing all cardboard containers and optional components secured to the system skid.
11
Carefully remove all components cut free in 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 mounted on 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.
25
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 equipment and system drain fixtures, do not place fork lift forks at the positions indicated by the CAUTION labels. Adjust the fork lift forks to their widest position. The Aquastorm 200 frame width is 152cm (59.9 inches) wide. Use fork extensions on forks if the forks do not extend at least seven (7) feet.
13
Once all jam nuts have been removed from the 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, carefully raise 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.
26
Aquastorm 200
7.1
INSTALLING THE SYSTEM LEVELING FEET

1 Locate and open the cardboard container labeled "Documentation Package Enclosed". Remove the system leveling feet (quantity 12) from the container.
Figure 29 - Leveling Foot
Install the leveling feet so they extend approximately 12.7cm (five {5} inches) from the base of the system frame. Be consistent with each leveling foot.
Figure 28 - Documentation Package
While the Aquastorm 200. system is still 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.
27
Aquastorm 200
SECTION 8
INSTALLATION/SETUP
Read this section in its entirety prior to performing any installation procedure.
WARNING
All procedures outlined in this section are to be performed in the order in which they are presented. Failure to do so may result in damage to the equipment or personal injury.
8.1
POSITIONING THE AQUASTORM 200

Carefully make the final adjustments positioning the Aquastorm 200 using a forklift so that the system will be in place for operation. The machine front and back sides should be facing correctly for required operation.
o
Using the fork lift, carefully position the Aquastorm 200 into place for installation. 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 site of installation. 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.
28
Installation Setup
Aquastorm 200
8.2
MAIN CABINET LEVELING PROCEDURE

1 On the "X" axis, place a level positioned on the underside corner of the Aquastorm 200 metal frame near the leveling foot. Make the necessary height adjustments at the base of the leveling foot hex head. Turn the leveling foot hex head clockwise to 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). Repeat the above steps for all four (4) corners of the system, front and rear. On the "Y" axis, place the level positioned on the underside corner of the Aquastorm 200 frame near a leveling foot. Make the necessary adjustments to the leveling feet to bring the system into level. Recheck the "X" axes to be sure the leveling at these points have not changed. Repeat the above steps as necessary.
Top View of Aquastorm 200 10.16 cm (4.0")
Base of Cabinet
Leveling Foot Hex Head
Figure 31 - Leveling Foot Adjustment
Figure 32 Twelve (12) Leveling Feet Locations Designated by this Symbol Installation Setup 29
Aquastorm 200
8.3
REMOVING THE SYSTEM PACKAGING 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. Remove the packaging materials from the locations outlined below.
Remove the foam padding from the windows and packaging tape from the surfaces of the cabinet.
CAUTION
To prevent unnecessary damage to the cabinet's polypropylene surfaces, use extreme caution when cutting strapping or removing packaging materials so as not to scratch or cut into the polypropylene surfaces.
Figure 34 - Removing the foam padding from the windows
Remove the plastic wrap from around the perimeter of the system.
Figure 33 - Removing the plastic wrap
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.
30
Installation Setup
Aquastorm 200
Remove the packaging from the tank area
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.
Fgure 35 - Tank Packaging
Remove packaging tape securing the sound enclosure lid and tool kit door.
Fgure 36 - Sound Enclosure and Tool Kit Door Packaging
Remove the packaging tape and foam padding from the optional spray wand in the sink.
Fgure 37 - Optional Sink Packaging Installation Setup 31
Aquastorm 200
8.4
INSTALLING THE DRAIN SCREENS

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 proper installation of the drain screens.
Figure - 39 Drain Screen
Locate and remove the drain screens from the contents of the cardboard container labeled "DOCUMENTATION PACKAGE ENCLOSED".
Install the two (2) prewash drain screens from 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.
Go to the rear of the system and remove the rear access panels. Remove the rear access panels starting with the panel closest to the entrance end.
4 5
Fgure 38 - Documentation Package Install 2 Drain Screens in the Prewash section via the Front Window
Remove each of the tank covers from their respective tanks. Install a drain screen in the bottom of each of the tanks. Replace the tank covers on each of the respective tanks
Figure 41 - Tank Drain Screen Locations
Figure 40 - Prewash Drain Screen Location
Install a Drain Screen in the Wash, Rinse, and Optional Chemical Isolation tanks from the rear of the system 32 Installation Setup
Aquastorm 200
8.5
OPTIONAL SUMP PUMP INSTALLATION
NOTE
Materials Required
610 cm (20 ') Maximum length of 1 /2" CPVC drain pipe Lengths of 1" facility drain pipe Teflon Tape CPVC Cement and Solvent
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.
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 customer supplied; 1 1/ 2" CPVC drain plumbing; 1" facility drain plumbing. Be sure to use Teflon tape on all threaded plumbing fittings. The Sump assembly is designed to be positioned at the exit end of the Aquastorm 200 system.
Position the sump pump assembly at the exit end of the system, with the drain pipe facing the exit end of the system. Install a union or coupling (customer 1 supplied) at the end of the 1 /2" drain plumbing at the exit end of the Aquastorm 200 system. 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. Connect the opposite end of the drain pipe 1 installed in step 4 to the 1 /2" NPTF fitting on the sump. Connect the 1.0" NPTF sump outlet to the facility 1.0" (customer supplied) drain or facility water treatment system. Locate the cable from the sump pump with the connector labeled PG27. Plug the connector labeled PG27 into the receptacle at the exit end of the Aquastorm 200 labeled PG27.
Sump Pump
Refer to Figure 42 on page 34 labeled "Sump Pump Installation" for steps 1 - 8 of this procedure.
If your system has been configured with the Optional Sump Pump, locate and remove the assembly from the shipment contents.
7 8
Installation Setup
33
Install a Union or coupling Here Connect Sump Inlet (11/2" NPTF) to Aquastorm 200's standard 1 1/2" NPTM, drain at the exit end of the cabinet Receptacle 1 1/2" CPVC drain from system to Sump (Customer Supplied) Sump Outlet 1.0" NPTF
Connector Cable
Connect Sump Outlet to 1.0" NPTF Facility Drain (Customer Supplied plumbing)
34 Figure 42 - Sump
Connect Plug #PG27 from Sump into Sump receptacle at exit end of cabinet labeled PG27
Sump Side View
Aquastorm 200
Installation Setup
Pump Installation
Aquastorm 200
8.6
OPTIONAL TREATMENT INTERFACE INSTALLATION
Materials Required
457 cm (15 ') Maximum length of 1 /2" CPVC drain pipe Lengths of 1" CPVC, schedule 80 facility drain pipe Lengths of 3/4 " CPVC, schedule 80 fill pipe Teflon Tape
Tools Required
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 assembly at the exit end of the system, with the drain pipe facing the exit end of the Aquastorm 200 system. Install a union or coupling (customer 1 supplied) at the end of the 1 /2" drain plumbing at the exit end of the Aquastorm 200 system. Install the required length of 1 /2" CPVC drain pipe (not to exceed 457 cm {15 '}), to the remaining end of the union or coupling. Connect the opposite end of the drain pipe 1 installed in step 4 to the 1 /2" NPTF fitting on the inlet side of the treatment interface. Connect the 1.0" NPTF treatment interface outlet to the optional CLS 1.0" inlet (See CLS installation manual for CLS fitting locations), using the customer supplied 1.0" plumbing. Connect the 3/ 4 " fill line from the Aquastorm 200 to the 3/4" NPTF fitting on the treatment interface using the 3 customer suppplied /4" plumbing. Connect the treatment interface 1 / 2" drain overflow to facility drain, or to the 1 optional sump pump's 1 / 2" inlet side drain plumbing. This connection is for high level overflow only.
1 1
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.
If your system has been configured with the 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
Installation Setup
35
10
Plug the PG26 connector into the receptacle at the exit end of the Aquastorm 200 labeled PG26.
Locate the cable from the treatment interface with the connector labeled PG26.
36
Receptacle Connect Plug #PG26 from the Treatment system into the receptacle at exit end of cabinet labeled PG26
Aquastorm 200
Inlet From Aquastorm Drain 1 1/2" NPTF Fill From Aquastorm 3/4" NPTF Outlet to CLS 1" NPTF
Installation Setup Figure 43 Treatment Interface Installation
System 1 1/2" Drain to Optional Sump or Facility Drain Drain Overflow 1 1/2" NPTF
Connector Cable Install Coupling Here
Pump
Outlet to CLS 1" NPTF
Inlet From Aquastorm Drain 1 1/2" NPTF
Drain Overflow 1 1/2" NPTF
Treatment Tank Side View
Aquastorm 200
8.7
OPTIONAL INLET CONVEYOR EXTENSION INSTALLATION

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.
While holding the spacers in place, position the idler shaft assembly removed in step 2. Align the mounting holes, then install the hardware removed in step 2, (29200-051-00-0, hex head bolts, 2-9232007-00-0, flat washers, 2-9233-005-000, lock washers) at either side of the inlet conveyor. Finger tighten the hex bolts at this time so that angle adjustment may be made. DO NOT TIGHTEN SECURELY.
Locate and remove the Adjustable Inlet Conveyor Extension and mounting hardware from the contents of the crate. Using a 13 mm box wrench, remove the hardware, (2-9200-051-00-0, hex head bolts, 2-9232-007-00-0, flat washers, 29233-005-00-0, 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.
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 (29237-004-00-0) from the top ends of the left hand threaded adjustment rods (512779-01).
NOTE
Take caution not to lose the Teflon spacers (525778-01) at either side of the inlet conveyor, since they need to be reinstalled. Do Not disassemble the Idler Shaft Assembly.
Align the holes in the ends of the left hand threaded adjustment rods (512779-01) with the mounting holes in the side panels (3-0787-220-01-6) of the inlet conveyor. Install the hardware removed in step 6 through 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.
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 200 cabinet. Utilize the vertical slotted mounting hole for installation (refer to Figure 43 - Inlet Conveyor Installation on page 37). Install the spacers (525778-01), quantity one (1) at either side of the inlet conveyor, between the inlet conveyor and entrance end mounting bracket.
Adjust the height of the Inlet Conveyor Extension to the required position by turning the turnbuckles. Once the inlet conveyor has been adjusted to the required operating position, use a 13 mm box wrench to tighten the hardware which was finger tightened in step 5.
10
Installation Setup
37
2-9233-005-00-0 M8 SST Split Lock Washer 2-9232-007-00-0 M8 SST Flat Washer
2-9200-051-00-0 M8 x 40 SST Hex Head Bolt
2-9237-004-00-0 M5 SST Hex Nut
Idler Shaft Assembly
525778-01 Spacer
38
512778-01 Right Threaded Height Adjust Rod Idler Shaft Assembly 512779-01 Left Threaded Height Adjust Rod 512780-01 Left and Right Turnbuckles
2-9290-011-00-0 8 x M6 x 20 Socket Head Shoulder Bolt
Aquastorm 200
3-0077-114-01-6 Conveyor Bracket
Installation Setup
3-0787-220-01-6 Side Plate
Figure 44 - Inlet Conveyor Installation
Aquastorm 200
8.8
OPTIONAL PHOTOCELL HOOK-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 the Aquastorm 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
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 with the M 5 hex nut (2-9237-004-00-0).
NOTE
Before operating the photocell, perform the Photocell Alignment procedure on page 2-14 of the Instruction Manual.
Detail "A"
Detail "A" M 5 Hex Nut 2-9237-004-00-0 (QTY 2) M 5 Flat Washer 2-9232-022-00-0 (QTY 4)
M 5 Pan Head Bolt 2-9210-030-00-0 ( QTY 2)
Figure 45 - Photocell Mounting
Photocell Mounting Bracket 523977-01 M 5 Lock Washer 2-9233-003-00-0 (QTY 2)
Installation Setup
39
Aquastorm 200
8.9
BOLT ON SOUND ENCLOSURE INSTALLATION

(Crated Shipments Only)
CAUTION
The sound enclosure is designed for removal prior to shipping for those shipments which are to be crated. For shipments that are received crated, perform this installation procedure. Refer to Figure 63 below for the installation of the sound enclosure. 3 1 The Sound Enclosure is to be installed using M6 metric hardware. Locate the 24 sets of M6 hardware inside the box labeled "Documentation Package".
Figure 63 - Sound Enclosure Installation
Heavy Object - The exit end sound enclosure is heavy. Arrange for three (3) or four (4) personnel to lift it into position, or use the appropriate rigging equipment to position the sound enclosure for installation.
Position the sound enclosure at the exit end of the Aquastorm 200 system cabinet as illustrated in Figure 63. Install two (2) M6 x 40 hex head bolts (29200-035-00-0) with M6 flat washers (29232-023-00-0) into the two (2) upper most corner mounting holes, from the inside of the sound enclosure. Use these two (2) holes to align the sound enclosure to the Aquastorm's exit end bulkhead mounting holes.
M6 Hex Nut 2-9237-005-00-0
M6 Flat Washer 2-9232-023-00-0
Bolt Thru Exit Bulkhead and Exit Enclosure (24 sets of hardware)
Sound Enclosure Bulkhead shown Blown out from Assembly to show Mounting hole Locations
M6 Lockwasher 2-9233-004-00-0 M6 Flat Washer 2-9232-023-00-0 M6 x 40 Hex Head Bolt 2-9200-035-00-0 Sound Enclosure
Aquastorm 200 Exit End Bulkhead Sound Enclosure Bulkhead
Close-Up Cut-Away View of Mounting Hardware Configuration 40 Installation Setup
Aquastorm 200
Secure the two (2) sets of hardware installed 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. Install all remaining, 22 sets, of hardware in the mounting holes illustrated in Figure 63 on page 40, then tighten securely.
Installation Setup
41
Aquastorm 200
8.10
CONVEYOR WIRE BELT INSTALLATION

(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.
Feeding the Wire Belt Feed the Wire Belt from the top of the co toward the exit end of the system, then a the underside of the conveyor, toward the end of the Optional Inlet Conveyor assemb
Open Side of Loop Facing Toward Entrance End Closed Loop Side Toward Exit End
NOTE
If your system is not configured with the Optional Inlet Conveyor Extension, the conveyor wire belt is not removed from the system for shipment, therefore it is not necessary to perform this procedure.
Locate and remove the roll of Conveyor Wire Belt from the contents of the shipment. Bring the roll of wire belt to the exit end of the Aquastorm 200. Arrange the wire belt so the Closed End of the Hook Loops are facing towards the EXIT end of the Aquastorm 200.
2 3
Entrance End
Exit End
Figure 46 - Wire Belt Installation 42 Installation Setup
Aquastorm 200
Manually feed the wire belt from the entrance end of the cabinet through the TOP PORTION of the conveyor first. Pull the wire belt all the way through the system to the exit end of the conveyor. Pull the wire belt through the system by reaching inside the window port of each stage and pulling the wire belt through.
Figure 47
Feeding the Wire Belt Feed the Wire Belt from the top of the conveyor toward the exit end of the system, then around the underside of the conveyor, toward the entrance end of the optional Inlet Conveyor assembly.
Feed over Top
Pull from Bottom
Bring the wire belt around to the bottom of the exit end of the conveyor, so that it hangs approximately 15.24cm (6 inches) over the end. Go to the entrance end at the Optional Inlet 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 and pulling the wire belt through.
Installation Setup
Make a loop in a portion of the belt at the conveyor exit end, then feed the belt through the bottom portion of the conveyor from the loop so that the belt is not turning the exit end driver rollers. Feed the remaining portion of the wire belt through the lower portion of the conveyor until the end of the wire belt extends over the Optional Adjustable Inlet Conveyor.
43
Aquastorm 200
10
Extend the wire belt over the Optional Adjustable Inlet Conveyor Extension until both ends meet on the top side of the inlet conveyor. Locate and remove the Wire Belt Connecting, Master Links supplied in the cardboard box labeled "DOCUMENTATION PACKAGE ENCLOSED" . Reference Electrovert Part Number 511611-01 for the Wire Belt Master Link Set.
Electrovert Part Number 511611-01 Wire Belt Master Link
11
Figure 48 - Wirebelt Master Links
12
Proceed to the "Wire Belt Splicing Instructions" for the correct Master Link Installation Procedure.
44
Installation Setup
Aquastorm 200
8.11
WIRE BELT SPLICING INSTRUCTIONS
DETAIL "A"
Install the wire belt splicing links as depicted (in a "U" shape) in photograph 1, ensuring that the loop ends of the splice links are in the same direction as the wire belt loops. DETAIL "A"
Splice Intersection Point
Splice Intersection Point
DETAIL "B"
Once both splicing links are in place, positioned in the "U" shape, pan tie the oposing ends of the wire belt together as depicted in photograph 2, to keep them from slipping apart while completing the wire belt splice. DETAIL "B"
Installation Setup
45
Aquastorm 200
3
DETAIL "C"
DETAIL "C" Tighten the pan ties to bring either end of the wire belt closer together until both ends meet, then pull the ends of the splice links through the links of the wire belt and spread the splice link ends apart.
Spread the ends of the Splice Link apart
Pull Splice Links through the belt here
Using a pair of needle nose pliers, grasp one (1) end of the splicing link and insert the loop end over the belt link being spliced.
Insert loop end of splicing link over belt link here
46
Installation Setup
Aquastorm 200
When the loop end of the splicing link is properly inserted, the loop end of the splicing link extends below the wire belt as depicted in photograph 5.
The loop end of the Splicing Link extends below the wire belt when properly inserted
6
Insert tip of screwdriver in the Splicing Link Loop
Using a small flat head screwdriver, as shown in photograph 6, insert the screwdriver under the wire belt link, opposite the side already looped and insert the tip of the screwdriver into the splicing link loop, applying a downward pressure on the loop by pulling upwards on the screwdriver handle.
Insert screwdriver here
Pull up on screwdriver handle
To complete the splice on one (1) end of the splicing link, while still applying pressure on the handle of the screwdriver with the tip of the screwdriver inserted in the link's loop, force the handle of the screwdriver over in the opposite direction to force the open end of the loop on the splicing link to catch the wire belt link that the screwdriver was inserted through in photograph 6. Repeat the steps outlined in photographs 4 thru 7 to connect the opposite end of the splicing link and both ends of the remaining splicing link.
Force handle of screwdriver in this direction leaving the tip of the screwdriver inserted in the loop of the link
Force the open end of the link's loop to catch the wire belt link here
Installation Setup
47
Aquastorm 200
Refer to the Wire Belt Connecting Link weaving instructions that follow for more details on installing the Wire Belt Connecting Links.
48
Installation Setup
Aquastorm 200
Installation Setup
49
Aquastorm 200
8.12
PUMP DRAIN PLUG INSTALLATION

During the cold weather months, the drain plugs for the wash and rinse section pumps are removed prior to shipment. This prevents any fluid remaining inside the pumps to drain completely and prevent freezing, resulting in damage to the pumps. Locate the two (2) drain plugs shipped within the documentation package. Install one (1) each in the bottom side of the wash and rinse pump.
50
Installation Setup
Aquastorm 200
8.13
FACILITY CONNECTIONS
This section provides step-by-step instructions for connecting facility power, exhaust and water to the Aquastorm 200 Aqueous Cleaning system. Perform the following procedures in the order in which they are presented. Failure to do so may result in damage to the equipment or personal injury. Read each procedure in its entirety before performing any installation procedures.
Fill and Final Rinse water supplies must be separate. Fill water supply temperature should be heated water to 60-71oC (140-160oF). Water supply temperature to the Final Rinse should be heated tap or treated water to 6071oC (140-160oF). 2
Connect the facility water supply to the 3/ " NPT Male CPVC Final Rinse Inlet 4 pipe or optional CLS (Closed Loop System).
Facility Water Hook-Up

Refer to the Installation Sales drawing included with the system's documentation package or refer to the typical installation drawing on page 12 of this manual for the steps that follow. Also refer to page 5 of this manual for water requirements and system specifications.
Connect the facility water supply to the 3/ " NPT Male SST Fill Inlet pipe. 4
Figure 49 - Facility Water Connections
NOTE
Electrovert recommends that serviceable unions (Customer Supplied) be attached to all plumbing connections. Serviceable Ball or Gate Valves (Customer Supplied) should be installed near or at the system connections on the appropriate pressure lines. Pressure gauges should be installed on the facility side of the services valves to monitor and verify availability.
Installation Setup
/4" NPT Male Final Rinse Connection
/ 4" NPT Male Fill Connection
Rear of Final Rinse with Access Panel Removed 51
Aquastorm 200
Rinse Hose
It will be necessary to rinse out the system periodically for preventive maintenance. This will require the use of a hose and spray nozzle. Such a clean-out hose should be installed in the vicinity of the system and be supplied with either hot and/or cold water. This hose must be used with deionized water to ensure that system cross contamination will NOT occur.
52
Installation Setup
Aquastorm 200
Facility Exhaust Hook-Up

Refer to the Installation Sales drawing included with the system's documentation package or refer to the typical installation drawing on page 12 of this manual for the steps that follow. Also refer to page 5 of this manual for Exhaust requirements and system specifications.
CAUTION
Do not walk or stand on the top side of the Aquastorm cabinet. Damage to the cabinet may result The top side of the cabinet is designed with internal exhaust plenums and is assembled from welded polypropylene.
Locate the two (2),25.4 cm (10") diameter exhaust ports at the top of the system. Connect the facility exhaust system to the exhaust ports as specified on page 5 of this manual.
Use an Inclined Manometer to verify the static pressure and SCFM ratings specified for each exhaust port as listed on page 5 of this manual.
25.4 cm (10") Diameter Exhaust Ports
Figure 50 - Facility Exhaust Connections
Installation Setup
53
Aquastorm 200
Facility Power Connection

Refer to page 6 in this manual for the schematic reference number and voltage which applies to your system electrical configuration. SystemGrounding The Aquastorm 200 Aqueous Cleaning system must be grounded in accordance with local, state and/or federal electrical codes, (i.e. National Electrical Code Rev. 1996). Ensure that the redundant ground for the immersion heaters is connected to the ground block which is provided inside the the high voltage electrical enclosure.
Immersion Heater Redundant Ground Connection
Main Power Disconnect 380 and 460 V Systems only
Main Ground Block
Figure 51 - Ground Connections
54
Installation Setup
Aquastorm 200
CAUTION
Before connecting facility power to the system, use a voltmeter to verify the incoming power agrees with the specifications indicated on the system serial tag.
NOTE
It is the responsibility of the user to provide any necessary conduit and conduit connectors to the 4" conduit fitting at the exit end of the Aquastorm 200 system.
Serial Tag Location
WARNING
Turn off the facility power at the facility breaker before connecting the facility power to the Aquastorm 200. Use safety lockouts on the fused safety disconnect for added protection. Do not operate the system or turn on power when access panels are open, except for brief periods when it is required for testing or to verify motor rotation. Use caution when shields, panels or covers are removed exposing electrical terminals or wires.
Attach the necessary conduit and conduit connectors to the fitting at the exit end of the cabinet, from the Aquastorm 200, to the facility power source. Bring the facility power wiring to the system through the conduit, then feed the wires through the conduit into the main power enclosure of the Aquastorm 200. The Main Power Enclosure houses the Main Power disconnect, to which power is to be connected (380 and 460 V systems only).
Connect the Facility Conduit and Connectors Here Feed Wiring from Facility Power Through the Conduit into the Main Power Enclosure at the Exit End Front Corner, base of the cabinet Figure 52 - Serial Tag, Conduit Connector, and Incoming Power Locations
Installation Setup
55
Aquastorm 200
3 4 5
Remove the system front access panels to allow access to the electrical enclosures. Open the main power enclosure. Connect the 3 phase electrical service to the primary power terminals of the Main Power Disconnect, labeled SW-01 , inside the main power enclosure. Make all ground conductor connections at the proper terminal strip, labeled GROUND , dedicated for this purpose.
NOTE
For 220 V systems it is the customer's responsibility to supply, instll, and connect the correct amperage disconnect for the Aquastorm 200.
Main Power Disconnect
SW-01 Connect Main Power Ground Here
Facility Power Wires Enter Here
GROUND
Incoming Power Side of Main Disconnect
Figure 53 - Main Power Connections
56
Installation Setup
Aquastorm 200
8.14
SYSTEM ELECTRICAL CHECK

Main Power 1
If you are not familiar with the Aquastorm 200 Aqueous Cleaning system electrical components and are somewhat unsure about performing the steps in this procedure, contact your local Electrovert Field Engineer listed at the front of this manual. Use a voltmeter to verify that the incoming power supply agrees with the specifications indicated on the System Serial Tag before activating facility power to the system. The System Serial Tag is located at the exit end of the Aquastorm 200 cabinet. CAUTION
which applies to your system voltage configuration.
Check each leg for proper voltage at the following test points:
L1 - L2 L2 - L3 L1 - L3 7
If system voltage is within specified tolerance, proceed to the next step in this procedure. If the system voltage does not meet specified tolerance indicated in step 4, verify that the facility power is as specified on the serial tag and rectify if necessary.
Operating the Aquastorm 200 at the incorrect voltage will result in damage to the equipment and void system warranty.
Figure 54 - System Serial Tag
DANGER
Hazardous voltage can shock, burn or cause death! Use extreme caution when performing voltage and amperage tests on live voltage.
3 4
Activate the facility power to the Aquastorm 200. Check the main power voltage at the incoming power side of the main disconnect labeled SW-01 , located inside the main power enclosure. Ensure the voltage reading is within +/- 10% of the voltage listed on the system serial tag. Refer to the system electrical schematic
Installation Setup 57
Aquastorm 200
NOTE
This manual makes reference to both standard and optional features. Disregard references to any features that are not configured with your system.
Locate the Circuit Breakers labeled CB 20 and CB 21 for the secondary side of the Control Voltage Transformer, and turn them to the OFF position. Activate power to the Aquastorm 200 at the System Disconnect. To check the secondary voltage, refer to the Aquastorm 200 Electrical Schematic #8-1679-006-01-2. Using a voltmeter, check the voltage from wire #10 on CB 20 to Neutral wire #2 on the TB, or from wire # 11 on the TB (Terminal Block) to Neutral wire #2 on the TB. The secondary voltage should be between 110 to 120 VAC. If secondary voltage is within the specified tolerance, proceed to the next step in this procedure.
5 6
Secondary Voltage 1 2 3
Turn off power at the System Power Disconnect. Remove the system front access panels. Using the access keys supplied with your system, unlock and open the main power electrical enclosure.
Secondary Power Breakers

Figure 55 - Secondary Voltage Testing
TB 20 CB 21 CB Wire #11
Wire #10
58 Installation Setup
Aquastorm 200
If the secondary voltage does not meet the specified voltages indicated in step 6, verify that the proper voltage tap is connected to the secondary side of the transformer.
7 8
Turn off power at the System Disconnect. Reactivate Circuit Breakers labeled CB 20 and CB 21 by switching it to the ON position.
NOTE
When performing amperage readings, the component being tested must be activated so a load is present on the circuit.
9 10
Turn on the power at the facility power safety disconnect. Use a Clamp Ammeter to check the amperage at each of the Contactor Wires for the Immersion Heaters, Pumps and Blowers in the High Voltage Panel. (Refer to the schematic panel lay out drawing on page 56, 8-1679-007-02-2; Note: this is a typical configuration for a 460 V system. For other voltages please refer to the schematics supplied with the documentation package shipped with your system).
WashImmersionHeaters OptionalC/IImmersionHeater RinseImmersionHeaters IRDryerRadiantHeaters Optional C/I Blower Blower #1 Blower #2 OptionalSumpPump OptionalTreatmentPump WashPump RinsePump CON-1 & 2 CON-5 CON-3 & 4 CON-6 CON-11 CON-9 CON-10 CON-12 CON-13 CON-7 CON-8
A~
300 mA
COM
Figure 56 - Clamp Ammeter
Installation Setup
59
L1 L1 L2
FU-1 Rinse 2 FU-1 Chem. Iso. IR Dryer FU-1
L2 L2 CB-7 Pump Wash Pump Rinse Blower 1 Blower 2 Chem.Iso. Blower Sump 1 CB-8 CB-9 CB-10 CB-11 CB-12 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2
L3
L1 L2
L3
L1
L2 L3
L1
L2
L3
L1
L2
L3
L1
L2 L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
L3 CB-13 Sump 2
L1
L2
L3
L1 L2
L3
L1
L2 L3
L1
L3
L1
L2
L3
L1
L2 L3
FU-1
FU-1
FU-1
Wash 1
Wash 2
Rinse 1
1 T1 T2 154 156 158 SS-7 SS-6 SS-9 SS-10 SS-11 160 162 164 166 168 170 172 174 176 178 180 182 T3 T1 T2 T3 T1 T2 T3 T1 T2 T3 T1 T2 T3
3 T1 T2 T3 184 186 188 SS-12 T1 T2 T3 190 192 194 SS-13
100 103 106 109 112 115 118 121 124 127 130 133 136 139 142 145 148 151
SS-4 A1 A2 A1 A2 A1 A2 SS-5 SS-6
SS-1
SS-2
SS-3
A1 A2
A1 A2
A1 A2
L1 L2 AUX-9 CON-5 T1 T2 T3 T1 T2 T3 T1 T2 T3 T1 T2 T3
A2 A2 2 2
L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3
L3 L1
L2
L3 L1
L2
L3 L1
L2
L3 L1
L1
L2
L3 AUX-11
L1
L2
L3
L1
L2
L3
60
CON-6 T1 T2 T3 CON-7 CON-8 CON-10 T1 T2 T3
A2 2
CON-1 T1 T2 T3
CON-2 T1 T2 T3
CON-3 T1 T2 T3
CON-4 T1 T2 T3
CON-12 T1 T2 T3 T1 T2 T3
CON-13 T1 T2 T3
A2
A2
A2
2 155157159
2 161163165
2 173175177
0 2/9 185187189
2 181193 195
101 104 107

4 A1 A2 A1 A1 A2 A2 4
110 113 116
119 122 125
128 131 134
137 140 143
146 149 152
2 167169 171 CON-9
2 179181183 CON-11 L1 TB-4 11 1 2 12
L3
1 13 25 90 8 13 43 21 31 A1 13 43 21 31 A1 CB-20 CB-21 CR-2 CR-10 FU-19 11 1 2 12 14 200 201 10 11 Chem. Iso. 2 2 Recirc. Option 60 14 44 22 32 A2 14 44 22 32 A2
Aquastorm 200
Installation Setup
L1 L2 L3 L1 L2 L3
A1
A2
A1
A2
A1
A2
L1 L2 L3
L1 L2 L3
L1 L2 L3
L1 L2 L3
CON-21 T1 T2 T3
A2 2 A2 A2
CON-22 T1 T2 T3
CON-23 T1 T2 T3
CON-24 T1 T2 T3
CON-25 T1 T2 T3
CON-26 T1 T2 T3
A2
A2
A2
102 105 108
111 114117
120 123126
129 132135
138 141144
147150 153
Drawing Number 8-1679-007-02-2

Figure 57 - High Voltage Panel Layout/ Test Points
Aquastorm 200
If amperage is drawn at each test point, and does not exceed the maximum amperage rating according to the schematic for your system configuration, proceed to the next step in this procedure. If amperage is drawn at each test point or amperage exceeds the maximum rating according to the schematic for your system configuration, contact your local Electrovert Service Technician, listed at the front of this manual.
Figure 58
8-.15 TION CHECK

NOTE
MOTOR ROTA-
Control Panel Quick Reference

Main Power On Wash/ Hurricane Pump On/ Off Wash Tank Fill Increase Temperature
After connecting the electrical service to the Aquastorm 200, it is necessary to verify the 3 Phases have been properly connected for correct rotation of the blowers and motors.
Main Power Off
Auto Sequential Mode
Wash JIC Pump On/ Off
Wash Tank Drain
WashTank Level Indicator
Decrease Temperature
Wash Tank Temp Level Indicator
Chemical Isolation Pump On/ Off Alarm Acknowledge
Photocell On/ Off
Chemical Isolation Tank Fill
Increase Temperature
Activate the facility power to the Aquastorm 200 via the system disconnect. Activate the facility exhaust system, then ensure the slide gate dampers are properly adjusted. Press the Main Power On Control, on the Custom Interface keypad. The Main Power On Indicator illuminates green to indicate power is activated.
Configurable Function Key
Chemical Isolation Blower On/ Off
Chemical Isolation Tank Drain
Chemical Isolation Tank Level Indicator
Chemical Isolation Tank Temp Level Indicator
Rinse/ Hurricane Pump On/ Off
Rinse Tank Fill
Final Rinse On/ Off
Rinse JIC Pump On/ Off
Rinse Tank Drain
Rinse Tank Level Indicator
Rinse Tank Temp Level Indicator
Press Blower #1 On/Off Control via the keypad to activate blower #1.
Sump Pump On/ Off Hi Level Indicator
Blower #1 On/ Off
Blower #2 On/ Off
IR Dryer On/ Off
Blower #3 On/ Off
Blower #4 On/ Off
IR Dryer Temp Level Indicator
Conveyor On
Conveyor Off
Conveyor Forward
Conveyor Reverse
Decrease Speed
Increase Speed
Installation Setup
61
Aquastorm 200
Motor Rotation Tag
Blower Motor Housing
Check Motor Rotation Here Figure 60 - Blower Rotation Tag Figure 61
Control Panel Quick Reference

Main Power On Wash/ Hurricane Pump On/ Off Wash Tank Fill Increase Temperature
Main Power Off
Figure 59 - Rear View of Blower Location If Applicable, Slide Blower Out First Before Checking Blower Rotation
Auto Sequential Mode
Wash JIC Pump On/ Off
Wash Tank Drain
WashTank Level Indicator
Wash Tank Temp Level Indicator
Chemical Isolation Pump On/ Off Alarm Acknowledge
The Blower Indicator illuminates green to indicate the blower is on.

Photocell On/ Off
Chemical Isolation Tank Fill
Go to the rear of the Aquastorm 200 cabinet and remove the access panels.
Chemical Isolation Blower On/ Off
Chemical Isolation Tank Drain
Chemical Isolation Tank Level Indicator
Chemical Isolation Tank Temp Level Indicator
Rinse/ Hurricane Pump On/ Off
Rinse Tank Fill
NOTE
If applicable to your system configuration, slide the blower out first, before checking blower rotation.
Final Rinse On/ Off
Rinse JIC Pump On/ Off
Rinse Tank Drain
Rinse Tank Level Indicator
Rinse Tank Temp Level Indicator
Verify that Blower Motor#1 is turning counterclockwise at the rear of the motor housing. The proper direction is indicated by a sticker on the motor housing. If it is turning clockwise or opposite the direction of arrow indication, press the Blower #1 On/Off Control to turn off the Blower #1.
Sump Pump On/ Off Hi Level Indicator
Blower #1 On/ Off
Blower #2 On/ Off
IR Dryer On/ Off
Blower #3 On/ Off
Blower #4 On/ Off
IR Dryer Temp Level Indicator
Conveyor On
Conveyor Off
Conveyor Forward
Conveyor Reverse
Decrease Speed
Increase Speed
62
Installation Setup
Aquastorm 200
The green Blower Indicator turns off to indicate the blower is off.
Safety Disconnect. Access the Main Power disconnect (SW01) in the main electrical enclosure, disconnect any two (2) phases, and reverse the connections. Recheck the rotation of all motors. If some of the motors are rotating clockwise and the remaining motors are rotating counterclockwise: Turn off the system power by pressing the Main Power Off Control. Turn off the main power at the system disconnect and at the Facility Power Safety Disconnect. Reverse any two (2) wires in the junction boxes of the motor(s) which are rotating clockwise. Recheck the rotation on all motor(s) which were rectified.
Repeat steps 4 - 6 for each motor and blower to ensure proper rotation. Blower #1 Blower #2 Optional Sump Pump Wash Pump Rinse Pump Optional Chem. Iso. Blower Optional Treatment Pump 3 4 7 1 2 5 6 MTR MTR MTR MTR MTR MTR MTR
If all motors are rotating in a counterclockwise direction, proceed to the next step.
If all motors are rotating in a clockwise direction: Turn off system power by pressing the Main Power Off Control. Turn off the main power at the system disconnect and at the Facility Power
9
Figure 62 - Power Phasing
After all motors have been checked, turn off the system main power at the Facility Power Safety Disconnect, then replace all
Main Power Disconnect
SW-01
Reverse any two (2) phases and reconnect
Installation Setup
63
Aquastorm 200
system access covers.asd
Other
Refer to the Aquastorm 200 Instruction Manual for operating instructions. Refer to the Aquastorm 200 Instruction Manual, Division 3 for Start-Up and Shut-Down procedures. Division 4 of the Aquastorm 200 Instruction Manual outlines Scheduled Maintenance, Corrective Maintenance, Troubleshooting and Calibration procedures.
64
Installation Setup

Aquastorm 200 Installation Manual

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Aquastorm 200

Electrovert Sales and Service Offices

Regional Service Centers

International Service Centers

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

Operation of this equipment exposes personnel to potential health hazards.

Pump and Blower Upgrade Level 1 Configuration

Voltage 220 VAC, 60 Hz 380 VAC, 50 Hz 460 VAC, 60 Hz

Pump and Blower Upgrade Level 2 Configuration

Voltage 220 VAC, 60 Hz 380 VAC, 50 Hz 460 VAC, 60 Hz

(2.0") 691 cm (272") 5 cm (2.0"

10.16 cm 154 cm (60.51")

Figure 1 - Cabinet Dimensions

Leveling Feet - 10.16 cm (4") Optional Inlet Conveyor 85.8cm (33.8")

Figure 2 - Inlet Conveyor Dimension 8 Technical Data

81.62 cm (32.13") 68.3 cm (26.7")

133.6 cm (52.1") Figure 3 - Treatment Interface Dimensions

Optional Sump Pump 61.6 cm (24") L x 42.5 cm (16.6") W x 61.8 cm (24.1") H

Figure 4 - Sump Pump Dimensions

6743/ 6681 (265.5/ 263.0)

787 1105 (30.7) (43.1) 1375 (53.6)

CLS Drain (Optional) 831 (32.4) Elec. Conn. 3" Conduit

Light Status Tower (Optional)

Final Rinse 432 (17.0)

Dryer #1 756 (29.8)

Dryer #2 752 (29.6)

Disconnect Elec. Conn. 3" Conduit 842 (32.8)

43 (1.7) System Drain

1537 (59.9) Frame

Figure 7 - Aquastorm 200 System Footprint Layout Drawing

INSTALLATION CHECK LIST

INSTALLATION CHECK LIST

COMPLETE UTILITY CONNECTIONS

EQUIPMENT/ TOOLS REQUIRED

TOOLS AND MATERIALS

Domestic Shipment Dimensions

SHIPPING WEIGHTS AND DIMENSIONS

Domestic Shipments Packaging Arrangement

Figure 8- Domestic Packaging Arrangement

- Contains the following:

Figure 9 - Documentation Package

International Shipments Packaging Arrangement

Figure 10 - Crated System

Figure 11 - System Documentation Package

INSTALLING THE SYSTEM LEVELING FEET

Figure 14 - Leveling Foot Installation Preparation 19

REMOVING THE SYSTEM PACKAGING MATERIALS

Figure 16 - System with Protective Plastic Wrapping

Remove the packaging from the tank area

Figure 17 - Tank Packaging Installation Preparation 21

Figure 18 - Exit End Packaging

Figure 19 - Optional Sink Packaging

Proceed to Section 7 "System Leveling".

CRATE DISMANTLING PROCEDURES

Cut along opposite sides and opposite ends

Figure 21 - Crate Dismantling

Figure 20 - Crate Dismantling Installation Preparation 23

Figure 22 - Crate Opened

INSTALLING THE SYSTEM LEVELING FEET

Figure 29 - Leveling Foot

Figure 28 - Documentation Package

POSITIONING THE AQUASTORM 200

MAIN CABINET LEVELING PROCEDURE