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7/31/2019 Aquastorm 200 Installation Manual
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Aquastorm 200
i
Manual Part Number2-9316-646-00-0
Text Part Number2-9316-645-00-0
Installation Manual
Copyright 1996 Electrovert
No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means: electronic, mechanical, photocopying, recording, scanning, or otherwise without the prior written
permission of Electrovert.
Published, October 25, 1996 by:
Electrovert U.S.A. Corp.
Aquastorm 200Aqueous Cleaning System
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Electrovert U.S.A. Corp.
P.O. Box 709, Highway 5 South
Camdenton, MO 65020-0709
ELECTROVERT
The Serial Tag information is to be filled in by the user for Technical Support purposes. Please have this
information available when contacting Technical Support or when placing parts orders.
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A q u a s t o r m 2 0 0
IN TRO DU CTIO NIN TRO DU CTIO NIN TRO DU CTIO NIN TRO DU CTIO NIN TRO DU CTIO NC o n g r a tu l at io n s o n y o u r p u r c h a se o f an A q u a st o r m 2 0 0 A q u e o u s C l e an i n g Sy st e m . T h e A q u a st o r m 2 0 0 i s a p o w e r f u le f fi cie n t a q u e o u s c le a n e r d e sign e d fo r t h e re m o v a l o f c o n ta m in a te d f lu id s an d p a r t i cle s le ft b e h in d f ro m w a v e so ld e r in g an d /o r r e f lo w p r o c e s se s o n c o m p l e x su r f ac e m o u n t a n d m i xe d t e c h n o l o g y P W A s . E ac h se c t io n o f t h e A q u a st o r m 2 0 0 h abee n care fu l ly in tegra ted and b a lanced to ach ieve the bes t c lean ing and d r y ing capab i l ity fo r i ts size and co s t , ava ilab le in th eindus t ry .
T h e p u rp o se o f t h is m a n u a l is t o h e lp o b ta in th e g re a te s t p o s sib le re tu rn o n y o u r i n v e s tm e n t . I t is su g g e ste d th a t n e wo p e ra to rs stu d y th e a p p l i ca b le s e c t io n s o f t h i s m a n u a l t h o ro u g h ly b e fo re o p e ra t in g th e e q u ip m e n t . I t i s f u r th e r s u g ge s te d
th a t t h e m a n u al b e u s e d a s a re fe re n c e b y m a in te n a n c e p e r so n n e l a n d a s a te x t fo r t r a in in g o f n e w m a in te n a n c e p e rs o n n e l
T h is m a n u a l i n c lu d e s o p e ra t in g in st ru c t io n s fo r t h i s e q u ip m e n t a v a ilab le a t t h e t im e th i s m a n u al w a s a p p ro v e d fo r p r in t i n gE le c t ro v e r t r e s e rv e s th e r i g h t t o m a ke c h a n g e s in d e s ig n a n d s p e c if ic at io n s an d /o r m a k e ad d i t i o n s to o r im p ro v e m e n ts in th e
p ro d u c t w i th o u t im p o sin g a n y o b l iga t io n s u p o n i t se l f t o i n s tal l t h e m o n p re v io u sly m a n u fa ctu re d p ro d u c ts .
Electro vert Sa les an d Service O fficesElectro vert Sa les an d Service O fficesElectro vert Sa les an d Service O fficesElectro vert Sa les an d Service O fficesElectro vert Sal es a nd Service O ffices
R e g i o n a l S e r v i c e C e n t e r sR e g i o n a l S e r v i c e C e n t e r sR e g i o n a l S e r v i c e C e n t e r sR e g i o n a l S e r v i c e C e n t e r sR e g i o n a l S e r v i c e C e n t e r s
N o r t h E ast R e g io n a l Se r v i ce C e n t e r
4 7 2 A m h e r s t St . Su i t e 6N ash u a, N H 0 3 0 6 3
F a x : 6 0 3 - 8 8 0 - 8 7 5 7
T e l : 6 0 3 - 8 8 3 - 2 4 8 8
South East Reg io na l Serv i ce C ente r2 0 0 Te c h n o l o g y D r.
A l p h ar e t t a, G A 3 0 0 0 5F a x : 7 7 0 - 4 4 2 - 1 9 8 7T e l : 7 7 0 - 4 7 5 - 6 1 0 0
N o r t h C e n t r al R e gio n a l Se r v ic e C e n t e r580-A To l lga te Road
E lg in , I L 601 23F a x : 8 4 7 - 2 8 9 - 3 7 9 7
T e l : 8 4 7 - 6 9 5 - 5 7 5 0
N o r t h W e st R e gio n a l Se r v ic e C e n t e r2 9 6 8 S co t t B lvd .Sa n t a C l ar a , C A 9 5 0 5 4F a x : 4 0 8 - 7 2 7 - 0 6 7 2
T e l : 4 0 8 - 7 2 7 - 4 6 5 0
So u t h W e s t Re g io n a l Se r v i ce C e n t e r
1 1 1 1 W . N o r t h C ar r ie r Pa rk w ayG r a n d Pr a ir ie , T X 7 5 0 5 0
F a x : 9 7 2 - 6 0 6 - 1 7 0 0
T e l : 9 7 2 - 6 0 6 - 1 9 0 0
E le c t r o v e r t M a in O ffic e sE le c t r o v e r t M a in O ffic e sE le c t r o v e r t M a in O ffic e sE le c t r o v e r t M a in O ffic e sE le c t r o v e r t M ai n O ffi ce s
Pr o d u c t & T e ch n o lo g y C e n t e rE le c t r o v e r t U S A C o r p .
1 1 1 1 W . N o r t h C a rr ie r Par k w a yG r a n d Pr a ir ie , T X 7 5 0 5 0
F a x : 9 7 2 - 6 0 6 - 1 7 0 0T e l : 9 7 2 - 6 0 6 - 1 9 0 0
Te ch n i cal Se r v i ce Su p p o r t G r o u p &C u s to m e r S e r v ic e Pa r ts D e p a r tm e n t
E le c t r o v e r t U S A C o r p .P. O . B o x 7 0 9C a m d e n to n , M O 6 5 0 2 0
F a x : 5 7 3 - 3 4 6 - 6 8 7 8T e l : 5 7 3 - 3 4 6 - 3 3 4 1
E d u ca ti o n a l Se r v i ce s & C u s t o m e r S u p p o r tC e n t e r
5 8 0 - A To l l ga t e R o a dE lg in , I L 60123F a x : 8 4 7 - 2 8 9 - 3 7 9 7
T e l : 8 4 7 - 6 9 5 - 5 7 5 0
I n t e r n a t i o n a l S e r v i c e C e n t e r sI n t e r n a t i o n a l S e r v i c e C e n t e r sI n t e r n a t i o n a l S e r v i c e C e n t e r sI n t e r n a t i o n a l S e r v i c e C e n t e r sI n t e r n a t i o n a l S e r v i c e C e n t e r s
N o r t h er n Eu r o p e & U . K.E le c t r o ve r t U . K . L t d .
T h e Te c h n o l o g y C e n t r eU n i t 1 , P incen ts K i ln I ndust r ia l Park
Pincen ts K i lnC a lco t , R e a d i n g
B e r ks ., U . K . R G 3 1 7 SOFa x: 4 4 1 1 - 8 - 9 3 0 - 1 4 0 1T e l : 4 4 1 1 - 8 - 9 3 0 - 1 4 0 0
E lec t rover t S ingapore1 0 K i an T e ck C r e sce n t
Sin g ap o r e 6 2 8 8 7 6Fa x : 6 5 - 8 6 1 - 7 3 3 7
Te l : 6 5 - 8 6 1 - 1 6 6 1
Japan
E le c t r o ve r t - S e it e c C o . , L t d .1 5 3 8 K a n o y a- c h oH ach io j i C i t y, To kyo 1 93 JAPAN
F a x : 8 1 - 4 2 6 - 2 3 - 8 3 5 0T e l : 8 1 - 4 2 6 - 2 3 - 7 7 2 2
N o r t h e r n Eu r o p eSpeed l ine Techn o log ies S .A .R.L .
6 5 A v e n u e d u G e n e r a l D e G a u lleI m m e u b l e le Pr o m e t h e e
7 7 4 2 0 C h a m p s - Su r M a r n e , Fr a n ceFa x : 3 3 1 6 0 - 0 5 - 6 1 2 9Te l : 3 3 1 6 0 - 0 6 - 8 1 8 1
C e n t r a l E u r o p eSp e e d l in e T e ch n o l o g i e s, G m b h
D a im le r st r asse 1 E D - 6 3 3 0 3D r e i e ic h , G e r m a n y
Fa x: 4 9 6 1 0 3 - 8 3 2 1 1 9Te l : 4 9 6 1 0 3 - 8 3 2 0
Speed l ine Techn o log ies It a lyV ia L igur ia 2 /2 8I - 2 0 0 6 8 Pe sc h ie r a B o r r o m e o ( M I )
I talyFa x :3 9 - 2 - 5 5 3 0 . 8 4 6 8
Te l : 3 9 - 2 - 5 5 3 0 . 8 3 3 9
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TABLE OF CONTENTS
SECTION 1 GENERAL ................................................................................................................................... 11.1 HAZARDS ........................................................................................................................................................... 11.2 SAFETY PRECAUTIONS ....................................................................................................................................... 3
SECTION 2 Technical Data ........................................................................................................................................... 52.1 Facility Requirements ........................................................................................................................................... 5
Water Requirements ..................................................................................................................................... 5Final Rinse ................................................................................................................................................... 5Fill .............................................................................................................................................................. 5System Drain ................................................................................................................................................ 5Exhaust Requirements ................................................................................................................................... 5Electrical Requirements ................................................................................................................................. 6Reference Schematics ................................................................................................................................... 6Power .......................................................................................................................................................... 6Capacities ................................................................................................................................................... 7Specifications ............................................................................................................................................... 7
2.2 Dimensions ......................................................................................................................................................... 8
SECTION 3 Installation Preparation ............................................................................................................................ 113.1 Receiving Instructions ......................................................................................................................................... 11
3.2 Installation Planning .......................................................................................................................................... 11System Footprint Drawing................................................................................................................................... 123.3 Installation Check List ........................................................................................................................................ 13
SECTION 4 Equipment / Tools Required ...................................................................................................................... 144.1 Protective Clothing ............................................................................................................................................ 144.2 Tools and Materials ........................................................................................................................................... 144.3 Expendable Items .............................................................................................................................................. 144.4 Rigging Equipment ............................................................................................................................................ 144.5 Maintenance ..................................................................................................................................................... 14
SECTION 5 Shipping Arrangement ............................................................................................................................. 155.1 Shipping Weights and Dimensions ...................................................................................................................... 15
Domestic Shipment Dimensions .......................................................................................................................... 15
5.2 Packaging Configuration.................................................................................................................................... 16Domestic Shipments Packaging Arrangement ....................................................................................................... 16International Shipments Packaging Arrangement .................................................................................................. 17
SECTION 6 Unpacking Procedures (Domestic Shipments Only) .................................................................................... 196.1 Installing the System Leveling Feet....................................................................................................................... 196.2 Removing the system Packaging Materials ........................................................................................................... 21
SECTION 7 Crate Dismantling Procedures (International Shipments Only) ................................................................... 237.1 Installing the System Leveling Feet....................................................................................................................... 27
SECTION 8 Installation / Set-Up ................................................................................................................................. 28
8.1 Positioning the Aquastorm 200 ............................................................................................................................................................................................. 28
8.2 Main Cabinet Leveling Procedure ....................................................................................................................... 29
8.3 Removing the System Packaging Materials........................................................................................................... 308.4 Installing the Drain Screens ................................................................................................................................ 328.5 Optional Sump Pump Installation ....................................................................................................................... 338.6 Optional Treatment Interface Installation ............................................................................................................. 358.7 Optional Inlet Conveyor Installation .................................................................................................................... 378.8 Optional Photocell Hook-Up .............................................................................................................................. 398.9 Bolt On Sound Enclosure Installation (Crated Shipments Only) .............................................................................. 408.10 Conveyor Wire Belt Installation (Crated Shipments Only) ...................................................................................... 428.11 Wire Belt Splicing Instructions ............................................................................................................................. 458.12 Pump Drain Plug Installation .............................................................................................................................. 508.13 Facility Connections .......................................................................................................................................... 51
Facility Water Hook-Up ..................................................................................................................................... 51Rinse Hose ....................................................................................................................................................... 52Facility Exhaust Hook-Up ................................................................................................................................... 53Facility Power Connection .................................................................................................................................. 54
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8.14 System Electrical Check...................................................................................................................................... 57Main Power ...................................................................................................................................................... 57Secondary Voltage ............................................................................................................................................ 58
8.15 Motor Rotation Check........................................................................................................................................ 61Other ............................................................................................................................................................... 64
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vi
LIST OF FIGURES
SECTION 2
Figure 1 - Cabinet Dimensions.................................................................................................... 8Figure 2 - Inlet Conveyor Dimension ........................................................................................... 8Figure 3 - Treatment Interface Dimensions.................................................................................... 9Figure 4 - Sump Pump Dimensions .............................................................................................. 9
SECTION 3
Figure 7 - Aquastorm 200 System Footprint Layout Drawing ..................................................... 12
SECTION 5
Figure 8 - Domestic Packaging Arrangement .............................................................................. 16Figure 9 - Documentation Package ........................................................................................... 16Figure 10 - Crated System ........................................................................................................ 17Figure 11 - System Documentation Package ............................................................................... 18
SECTION 6
Figure 13 - Leveling Feet in Documentation Package .................................................................. 19Figure 14 - Leveling Foot .......................................................................................................... 19Figure 16 - System with Protective Plastic Wrapping .................................................................... 21Figure 17 - Tank Packaging ...................................................................................................... 21Figure 18 - Exit End Packaging.................................................................................................. 22Figure 19 - Optional Sink Packaging ......................................................................................... 22
SECTION 7
Figure 20 - Crate Dismantling ................................................................................................... 23
Figure 21 - Crate Dismantling ................................................................................................... 23Figure 22 - Crate Opened........................................................................................................ 24
Figure 28 - Documentation Package ......................................................................................... 27Figure 29 - Leveling Foot .......................................................................................................... 27
SECTION 8
Figure 31 - Leveling Foot Adjustment ......................................................................................... 29Figure 32 - Twelve Leveling Feet Locations ................................................................................. 29Figure 33 - Removing the Plastic Wrap ...................................................................................... 30Figure 34 - Removing the foam padding from the windows ......................................................... 30Figure 35 - Tank Packaging ...................................................................................................... 31
Figure 36 - Sound Enclosure and Tool Kit Door Packaging .......................................................... 31Figure 37 - Optional Sink Packaging ......................................................................................... 31
Figure 38 - Documentation Package ......................................................................................... 32Figure 39 - Drain Screen .......................................................................................................... 32Figure 40 - Prewash Drain Screen Location ................................................................................ 32
Figure 41 - Tank Drain Screen Locations .................................................................................... 32Figure 42 - Sump Pump Installation ........................................................................................... 34
Figure 43 - Treatment Interface Installation ................................................................................. 36Figure 44 - Inlet Conveyor Installation ....................................................................................... 38Figure 45 - Photocell Mounting ................................................................................................. 39Figure 63 - Sound Enclosure Installation .................................................................................... 40
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Figure 46 - Wire Belt Installation ............................................................................................... 42
Figure 47 - Feeding the Wire Belt .............................................................................................. 43Figure 48 - Wire Belt Master Links ............................................................................................. 44
Wire Belt Splicing Photographs ................................................................................................ 45 - 47
Photograph 1 .......................................................................................................................... 45Photograph 2 .......................................................................................................................... 45Photograph 3 .......................................................................................................................... 46Photograph 4 .......................................................................................................................... 46Photograph 5 .......................................................................................................................... 47Photograph 6 .......................................................................................................................... 47Photograph 7 .......................................................................................................................... 47
Wire Belt Company of America Illustrations............................................................................... 48 - 49Illustration 1 - 3 ....................................................................................................................... 48Illustration 4 - 7 ....................................................................................................................... 49
Figure 50 - Facility Exhaust Connections .................................................................................... 53Figure 51 - Ground Connections .............................................................................................. 54
Figure 52 - Serial Tag, Conduit Connector, and Incoming Power Locations ................................... 55Figure 53 - Main Power Connections......................................................................................... 56Figure 54 - System Serial Tag .................................................................................................... 57Figure 55 - Secondary Voltage Testing ....................................................................................... 58Figure 56 - Clamp Ammeter ..................................................................................................... 59Figure 57 - High Voltage Panel Layout/ Test Points ...................................................................... 60Figure 58 - Control Panel Quick Reference ................................................................................ 61Figure 59 - Rear View of Blower Location................................................................................... 62Figure 60 - Blower Rotation Tag ................................................................................................ 62Figure 61 - Control Panel Quick Reference ................................................................................ 62
Figure 62 - Power Phasing ........................................................................................................ 63
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General 1
DANGER High Voltage:
Installation of this equipment involves exposure to High Voltage. High voltage can shock, burnor cause death. Use extreme caution when performing voltage and amperage tests on livevoltage. These procedures must be performed only by an authorized electrician, electricalengineer or service technician familiar with testing live voltage.
SECTION 1 GENERAL
1.1 HAZARDS
Operation of this equipment exposes personnel to potential health hazards.
WARNING Risk of Electric Shock:
Installation of this equipment exposes personnel to situations which may result in electrical
shock if procedures are not properly followed. Pay close attention to Warnings of this naturethroughout the context of this manual.
When performing tests using ammeters, volt meters or ohm meters, electrical shock hazard ispresent. These procedures must be performed only by an authorized electrician, electricalengineer or service technician familiar with testing live voltage.
WARNING Skin Irritation:
When using certain chemicals such as descalers or saponifiers, it is important to follow the
MSDS (Material Safety Data Sheet) guidelines for proper handling and usage. Appropriateclothing and safety articles must be worn when using descaler and saponifier solutions. Skin oreye irritation will occur if not handled properly.
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2 General
WARNING Hot Surfaces/Burn Hazard:
During normal operation this equipment and some of its components operate at temperatures
up to 60-71o
C (140-160o
F). The operator must use extreme caution and wear therecommended safety garments prior to coming in contact with hot surfaces or components.Closely follow and adhere to the Warnings in this manual which pertain to hot surfaces.
Use extreme caution when working around or with hot components. Allow hot components tocool before handling whenever possible.
WARNING Heavy Objects:
When attempting to move heavy equipment or components, it is imperative to use the properrigging equipment. Do not attempt to move skids or large assemblies without the use of a forklift or other rigging equipment. Hand lifting will cause serious personal injury.
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General 3
1.2 SAFETY PRECAUTIONS
Electrical work should only be performed by a qualified electrician.
Prior to applying power for the first time, ensure that the system is properly grounded.
Post "NO SMOKING" signs in the work area and provide measures for enforcement.
Exercise Caution when using strong cleaning agents, solvents and other chemicals. Material Safety Data
Sheets (MSDS) contain specific uses and safety precautions which must be thoroughly understood and
strictly followed. If in doubt about any Caution, contact the manufacturer for clarification.
Avoid prolonged skin contact and inhalation of chemicals and fumes.
Operating this equipment may introduce burn hazards. Avoid contact with all hot surfaces, hot water and
steam. The viewing glass will reach temperatures in excess of 71o C (160o F). Extreme caution should be
taken to avoid touching the glass surfaces. Water temperatures will reach and/or exceed 71
o
C (160
o
F)Steam may escape from the system cabinet when windows are opened during operation or for maintenance
procedures. Steam will cause serious burns. Avoid contact with steam.
Protective clothing is required for servicing hot machine components or areas of the machine which come in
contact with chemical applications . Protective clothing includes ANSI (American National Standard Institute)
approve Safety Goggles, NIOSH or MSHA Approved Respirator, Steel Toe Safety Shoes, High Temperature
Acid and Water Resistant Gloves, Apron and a Long-Sleeved garment.
Fumes can be generated from certain saponifiers, defoamers, descalers, cleaning solvents, etc., during
operation. Precautions must be taken to avoid accumulation of flammable vapors. Whenever harmful fumes
are present, a proper extraction (exhaust) system must be provided. Refer to the manufacturer MSDS for
information and safety precautions concerning their products and system exhaust specifications.
Refer to specific Chemical Manufacturers Material Safety Data Sheets for disposal and/or removal and
handling of waste materials resulting from chemical operating processes.
Under the previously mentioned circumstances, all operators should be provided with an NIOSH or MSHA
Approved Respirator, to provide the operator effective protection from airborne residue resulting from
certain saponifiers, defoamers, descalers, cleaning solvents, etc.
NOTE: The above mentioned types of chemicals and cleaning agents recommended for
use with the Aquastorm 200 are not products of Electrovert. Please refer to
the specific chemical manufacturers MSDS (Material Safety Data Sheets) forthe specific use, handling, and safety procedures for their applications.
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4 General
WARNING Warning notices are used in this manual to emphasizehazardous voltages, high currents, high temperatures orother conditions that could cause personal injury.
DANGER Danger notices are used in this manual to warn theoperator that DEATH may result if a procedure is omittedor improperly performed.
CAUTION Caution notices are used to call attention to a situationthat could cause damage to the equipment.
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Technical Data 5
2.1 FACILITY REQUIREMENTS
Water Requirements
NOTE The Fill and Final Rinsewater supplies must be
separate.
NOTE The immersion heaters in
the Recirculating Wash
and Rinse tanks will heat
incoming tap or treated
water after an initial
waiting period.
Electrovert recommendssupplying heated water 60
- 71o C (140 - 160o F) to
the Recirculating Wash,
Rinse, and optional
chemical isolation tanks in
order to maintain
operating temperatures.
Final Rinse
Schedule 80, 3/4" NPT, CPVC pipe
User supplied, heated tap or treated water to
Final Rinse.
Temperature 60 - 71o C (140 - 160o F)
Flow Rate 11 - 19 L/Min (3 - 5 Gal./Min..)
Nominal Pressure 2.8 - 3.3 kg/cm2
(35 - 40 PSI)
Fill
Schedule 80, 3/4" NPT, CPVC pipe
Heated water to 60 - 71o C (140 - 160o F)
System Drain
Common 1 1/2" NPT, CPVC pipe;
38 L/Min. (10 GPM) constant
SECTION 2 TECHNICAL DATA
Exhaust Requirements
NOTE The following exhaustspecifications are to assist
the customer in specifying
an exhaust blower capable
of exhausting the system
All exhaust
measurements are
measured at the machine
exhaust port.
NOTE An independent, separate
blower is recommended
for this equipment due to
the high volume
requirements and
condensate build up
resulting from normal
operation of this
equipment.
Contact your local HVAC
specialist for blowerrequirements and
ventilation hook-up.
Recommended venting material - 25.4 cm (10 ")
diameter, seamless stainless steel or PVC air duct
Total system requires 68M 3/min. @ 2.5 cm
(2400 SCFM @ 1") H2O static pressure.
Port #1 - 34M 3/min. @ 2.5 cm (1200 SCFM
@ 1.0") H2O static pressure.
Port #2 - 34M 3/min. @ 2.5 cm (1200 SCFM
@ 1.0" ) H2O static pressure.
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6 Technical Data
PowerStandard Configuration
Voltage F.L.A. Total KVA Recommended Service
220 VAC, 60 Hz 264 100.6 325
380 VAC, 50 Hz 152 100.6 200
460 VAC, 60 Hz 126 100.6 150
Pump and Blower Upgrade Level 1 Configuration
NOTE This configuration upgrades the Wash and Rinse pumps to 10 HP; Dryer blowers
to 10 HP; adds an IR Dryer to Dryer #2; adds a 7.5 HP Enhanced ChemicalIsolation blower and a tank immersion heater.
Voltage F.L.A. Total KVA Recommended Service
220 VAC, 60 Hz 315 120 400
380 VAC, 50 Hz 182 120 250
460 VAC, 60 Hz 150 120 200
Pump and Blower Upgrade Level 2 Configuration
NOTE This configuration upgrades the Wash and Rinse pumps to 10 HP; adds an IRDryer to Dryer #2; the blower in Dryer #1 is upgraded to 15 HP; adds the
Enhanced Chemical Isolation tank immersion heater.
Voltage F.L.A. Total KVA Recommended Service
220 VAC, 60 Hz 360 136 450
380 VAC, 50 Hz 206 136 275
460 VAC, 60 Hz 171 136 225
Electrical Requirements
Standard Electrical Configuration:
460 VAC, 3 PH, 60 Hz
Optional Electrical Configuration:
220 VAC, 3 PH, 60 Hz
380 VAC, 3 PH, 50 Hz
Reference Schematics
VOLTAGE DRAWING #
460V, 60Hz 8-1679-006-01-2
220V, 60Hz 8-1679-005-01-2
380V, 50Hz 8-1679-003-01-2
Panel Layout 8-1679-004-01-2
NOTE It is the responsibility of
the customer to provide a
system electrical
disconnect capable of
protecting the Aquastorm
200 at the amperages
specified for 220 V
electrical configurations.System disconnects are
only provided with 380
and 460 V systems.
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Technical Data 7
Capacities
Recirculating Wash Tank - 300 Liter (80 gallon)
Optional Enhanced Chemical Isolation Tank -
95 Liter (25 gallon)
Recirculating Rinse Tank - 189 Liter (50 gallon)
Optional Sump Pump - 38 Liter (10 gallon)
Optional Treatment Interface Tank - 66.24 Liter
(17.5 gallon)
Specifications
Wash Pump -
Standard - 5 HP @ 220 L/Min. (58 gpm)
Hurricane - 10 HP @ 439 L/Min. (116 gpm)
Wash Heaters - (2) 16 KW Heaters; 32 KWTotal
Optional Enhanced Chemical Isolation
Tank Heater - (1) 16 KW Total
Rinse Pump -
Standard - 5 HP @ 220 L/Min. (58 gpm)
Hurricane - 10 HP @ 439 L/Min. (116 GPM)
Rinse Heaters - (2) 16 KW Heaters; 32 KW
Total
Optional Drag-Out Blower - 7.5 HP, 3 Ph
460 VAC, 500 CFM Turbine Blower
Dryer #1 Blower -
Standard - 7.5 HP, 3 Ph, 460 VAC , 500 CFM
Turbine Blower
Option 1 - 10 HP, 3 Ph, 460 VAC, 600 CFM
Turbine Blower
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 Wat
Radiant Heater panels; 3.6 KW Total
Conveyor - 1/8
HP, 90 VDC Motor, 0 - 3.65
MPM (0-12 FPM) (0 - 4.57 Meters/Min.)
CheckMate Conveyor - (2), 1/8
HP, 90 VDC
Motors, 0-15 FPM (0 - 4.57 Meters/Min.)
Sump Pump - 3/4
HP, 3 pH, 460 VAC, 50
gpm (189 L/Min.)
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8 Technical Data
2.2 DIMENSIONS
Main Cabinet [Frame] - 600 cm (236.38")
L x 154 cm (60.51") W x 128 cm
(50.24") H
Main Cabinet, Control Panel, and Sound
Enclosure overall dimensions - 691 cm
(272")
Leveling Feet - 10.16 cm (4")
Optional Inlet Conveyor 85.8cm (33.8")
600 cm
(236.38")
5 cm (2
128 cm
(50.24")
154 cm
(60.51")
691 cm (272")
5 cm (2.0")
10.16 cm (4.0")
Optional Status Tower - 58.9cm (23.2")
from top of Main Cabinet
Exhaust Vent - 5 cm (2.0") from the top ofthe Main Cabinet
91.44 cm(36.0")
Figure 1 - Cabinet Dimensions
Figure 2 - Inlet Conveyor Dimension
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Aquastorm 200
Technical Data 9
133.6 cm (52.1")
68.3 cm (26.7")
81.62 cm (32.13")
Optional Treatment Interface system -
133.6 cm (52.1") L x 68.3 cm (26.7") W x 81.62
cm (32.13") H
Optional Sump Pump -
61.6 cm (24") L x 42.5 cm (16.6") W x
61.8 cm (24.1") H
Figure 3 - Treatment Interface Dimensions
Figure 4 - Sump Pump Dimensions
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Installation Preparation 11
Aquastorm 200
SECTION 3 INSTALLATION PREPARATION
3.1 RECEIVING INSTRUCTIONS
Upon receipt, the system should be thoroughly
inspected. If damage or loss are detected, enter
all details on the freight bill or receipt, then have
it signed by the carrier's agent. Failure to follow
this procedure may result in the carrier's refusal
to honor the claim. The carrier will furnish the
necessary forms for filing a claim.
When damage is not readily apparent until the
equipment has been unpacked, a claim for
concealed damage must be filed. Make a written
or telephone request to the carrier for inspection
as soon as the damage is discovered. This type ofclaim must be done within 48 hours of delivery.
Keep all cartons, packing materials and
paperwork. The carrier will furnish an inspection
report and the necessary forms for filing the
concealed damage claim.
3.2 INSTALLATION PLANNING
Al locate suff ic ient floor space to operate
efficiently and to allow accessibility to the system
from all sides. Refer to the system footprint
drawing supplied with the Documentation
Package.
Domestic shipments are on wheels, whereas
International shipments are on skids and in
wooden crates. The system leveling feet are
packaged in a separate container within the
shipment on domestic shipments.
System operation and maintenance functionsrequire additional space for system access. Allow
for an additional 0.9 meters (3 feet) clearance
behind and around the system, except where the
system is in-line with other automated equipment
i.e., wave/reflow soldering equipment. Refer to
the system footprint drawing on the following
page.
In selection of the site location, keep in mind the
requirements that must be provided at the site
i.e., electrical access, facility exhaust, drain, leve
surface, etc.
When considering a site for installation, it is also
important to check the flammability of the
materials to be used during operation or
maintenance, so as to provide adequate protection
for the system as well as personnel protection.
Note that in many instances the process of
cleaning can involve potentially hazardous liquid
materials requiring special handling and
treatment prior to disposal.
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12 Installation Preparation
Aquastorm 200
LightStatusT o
wer(Optional) C
on
veyorExtension
(Optional)
Inlet
Connections
1537
(59.9)
Fram
e
1060
(41.3)
105
(4.1)
20
(.8)
1276
(49.8)
58
9
(23.0)
1
327
(5
1.8)
1185
(46.2)
842
(32.8
)
248
(9.7
)
102/127
(4.0
/5.0)
AdjustableLe
gs
457
(17.8
)
Con
trolPanel
194
(7.6)
1175
(45.8)
54
8
(21.4)
Prewash
55
9
(22.0)
1059
(41.3)
Wash
1219
(48.0)
Chem
icalIso.
889
(35.0)
1095
(42.7)
1054
(41.1
)
6004
(234
.2)
Frame7
478
(291.6)
7540
(29
4.1)
5944
(231.8)
Rinse
1219
(48.0)
Electric
alCabinet
Access
Area
ElectricalCa
binet
AccessArea
267
(10.5)
ExhaaustP o
rt
(2PL)
11
56
(45.1)
SystemD
rain
1056
(41
.2)
1238
(48.3)
43
(1.7)
135
(5.3)
842
(32.8)
Exit
Disconn
ect
Elec.Conn.
3"Co
nduit
508
(19.8)
Final
Rinse
432
(17.0)
Dryer#1
756
( 29.8)
Dryer#2
752
(29.6
)
1820
(71.0)
60
(2.3)
831
(32.4)
Elec.
Conn.
3"Conduit
CLSD
rain(Optional)
FinalRinseLine
FillLine
ToRinse
Ex t
.FeedC.I.
Line(Op
tional)
SplitFillLine
ToW
ash
(Optional)
305
(11.9) 7
87
(30.7)
1105
(43.1)
1375
(53.6
)
Std.Drain
Blower
Slide
Ac
cess
Area 6
10
(23.8)
445
(17.4)
445
(17.4)
1518
(59.2)
BlowerSlide
AccessArea
1903
(74.2)
2985
(116.5)
610
(23.8)
445
(17.4)
4030
(157.2)
42
70
(166.5)
439
0
(171.2)
4488
(17
5.0)
4584
(178. 8
)
5359
( 209.0)
6743/6681
(265.5/
263.0)
137/75
(5.4/3.0)
1575
(61.4)6
32
(24
.6)
StandardInletConv e
yor
Figure7-
Aquastorm2
00S
ystemF
ootprintLa
youtDrawing
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Installation Preparation 13
Aquastorm 200
3.3 INSTALLATION CHECK LIST
The following check list is provided for organizational and record keeping
purposes. Failure to record problems with installation or factors required for
proper installation may result in unscheduled down time.
INSTALLATION CHECK LIST
LOCATION SHIPPING DAMAGE
Check For: Check for damage to system:
Adequate floor space
Adequate clearance above and around system
Level surfaces at installation site
Adequated facility connections for
Exhaust
Electrical Hook-Up
System Fill
System Drain
Final Rinse
If any of these requirements are inadequate,please describe:
If damage is found, please describe:
SYSTEM LEVELINGLevel "X" Axis at entrance end of system cabinet
Level "Y" Axis at front of system cabinet
Level "X" Axis at exit end of system cabinet
Level "Y" Axis at rear of system cabinet
Adjust leveling feet and re-check axis on all sides
COMPONENT INSTALLATION
COMPLETE UTILITY CONNECTIONS
DOMESTIC SHIPMENTS
Leveling Feet
Drain Screens
Optional Sump Pump system
Optional Treatment Interface system
Optional Single Add-On Dryer Module
Optional Dual Add-On Dryer Module
Pump Drain Plugs
CRATED SHIPMENTS (International Only)
Conveyor Wire Belt (for crated shipments withOptional Inlet Conveyor)
Optional Inlet Conveyor assembly
Optional Photocell
Drain Screens
Optional Sump Pump and plumbing
Optional Treatment Interface System
Optional Single Add-On Dryer Module
Optional Dual Add-On Dryer Module
Bolt on Sound Enclosure
Exit End Conveyor Drive Assembly
Pump Drain Plugs
Verify system voltage, phase and Hz rating
Check electrical power connections
Check for proper Power connections
Water connections
Drain connections
Exhaust connections
Pump & Blower rotation
NOTES:
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14 Installation Preparation
Aquastorm 200
4.1 PROTECTIVE CLOTHING
ANSI (American National Standard Institute)
Approved Safety GlassesSteel Toe Safety Shoes
Acid Resistant Smock
Long-Sleeved Garment
Heat Protective Gloves
4.2 TOOLS AND MATERIALS
Flat Blade Screwdriver
Phillips Head Screwdriver
Channel Lock Pliers
Pipe Wrenches
Teflon Tape
Schedule 80, CPVC Piping
(for Fill - 3/4", Final Rinse - 3/
4", and
Drain - 1 1/2")
Electrician's Pliers
Needle Nose Pliers
Wire Cutters and Strippers
Volt-Ohm Meter
Clamp Ammeter
Carpenter's Level
Allen Wrench (Hex) Set
Adjustable Wrenches (7/16" - 1 1/8")
(For International Shipments the
additional Tools are also required)
Pry Bars
Claw Hammers
Circular Saw (Rip Cut Blade)
4.3 EXPENDABLE ITEMS
Lint-Free Cloths
Glass CleanerSaponifier
Scale Stripper
Defoamer
4.4 RIGGING EQUIPMENT
(Domestic Shipments)
2 Ton Capacity (minimum) Fork Lift
(International Shipments)3 Ton Capacity (minimum) Fork Lift
4.5 MAINTENANCE
Heavy Duty Hose (3/4") Nozzle and Storage Reel
SECTION 4 EQUIPMENT/ TOOLS REQUIRED
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Installation Preparation 15
Aquastorm 200
SECTION 5 SHIPPING ARRANGEMENT
Domestic shipments of the Aquastorm 200 are
configured with wheels for easy maneuverability.
The entire system is wrapped in moisture
absorbent polyethylene for protection during
transit.
International (overseas) shipments of the
Aquastorm 200 are skidded and also wrapped
in the moisture absorbent polyethylene for
protection during transit. The system is
encapsulated in a wooden crate to ensure safe
arrival to its destination.
Follow the procedures which apply to your
shipment destination.
It is the responsibility of the customer to provide
any rigging devices required to transport theskidded system to the site of installation.
WARNING Move the Aquastorm 200 systemcrate using a fork lift. This equipmentis extremely heavy and attempting tohand lift will result in personal injury.Transport the Aquastorm 200 system
crate to the site of installation using afork lift.
CAUTION Do Not open crates prior to movingthem to their final site of installationor damage may occur.
5.1 SHIPPING WEIGHTS ANDDIMENSIONS
NOTE This manual makes
reference to both standard
and optional
configurations. Disregard
options which do not apply
to your system
configuration.
Aquastorm 200 systems are shipped as one
unit. Some standard and optional components
are removed from the system prior to shipment
Refer only to installation instructions which apply
to your system configuration.
NOTE All weights and
dimensions are
approximated figures and
are to be used as reference
only.
Domestic Shipment Dimensions
Cabinet Length 684 cm (269")
Cabinet Width 158 cm (62")
Cabinet Height 145 cm (57")
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16 Installation Preparation
Aquastorm 200
o Cardboard Box Labeled "Documentation Package Enclosed - Contains the following:
o System Documentation Package
o High Voltage Electrical Schematics
o Control Voltage Electrical Schematics
o System Installation Drawing
o
Instruction Manualo Bill Of Materials (BOM) Manual
o Assembly Drawings
o (2 Sets) Wire Belt Connecting Master Links
o (5) Drain Screens
o (12) Main Cabinet Leveling Feet
o (4) Optional Single Add-On Dryer Module Leveling Feet
o Set of Optional Single Add-On Dryer Module Interface Hardware
o (12) Pads for Leveling Feet
o (4) Pads for Optional Single Add-On Dryer Module Leveling Feet
o (2 Sets) Optional CheckMate Conveyor Connecting Master Links
Domestic Shipments Packaging Arrangement
o Main Cabinet ......................................................................................................................On Wheels
o Optional Add-On Single Dryer Module..................................................................................On Wheels
o Optional Add-On Dual Dryer Module ....................................................................................On Wheels
o Optional Sump Pump .......................................................................................On Van wrapped in pads
o Optional Sump Pump Plumbing, rubber unions and Hose Clamps ....................................... Loose on Van
o Optional Treatment Interface system ................................................................................. Loose on Van
5.2 PACKAGING CONFIGURATION
NOTE This manual makes reference to both standard
and optional configurations. Disregard options
which do not apply to your system configuration.
The following is an itemized list of components removed from the system prior
to shipment for shipping purposes, and how they are packaged so that
components may be easily located and identified:
Figure 8- Domestic Packaging Arrangement
Figure 9 - Documentation Package
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Installation Preparation 17
Aquastorm 200
International Shipments Packaging Arrangement
o Main Cabinet ................................................................................................. Bolted to skid and crated
o Optional Add-On Single Dryer Module............................................................. Bolted to skid and crated
o Optional Add-On Dual Dryer Module ............................................................... Bolted to skid and crated
o Roll of Conveyor Wire Belt....................................................... In a cardboard container strapped to skid
o Opitonal Adjustable Inlet Conveyor Extension ............................ In a cardboard container strapped to skid
o Exit End Sound Enclosure ................................................................ Strapped to Skid on inside of crate
o Exit End Conveyor Extension .............................................................Strapped to skid on inside of crate
o Optional Sump Pump system..............................................................Strapped to skid on inside of crate
o Optional Treatment Interface system ................................................... Strapped to skid on inside of crate
o Optional Roll of CheckMate Conveyor Wire Belt ........................ In a cardboard container strapped to skid
Figure 10 - Crated System
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18 Installation Preparation
Aquastorm 200
o Cardboard Box Labeled "Documentation Package Enclosed"
- strapped to skid inside of crate Contains the following:
o System Documentation Package
o High Voltage Electrical Schematics
o Control Voltage Electrical Schematics
o System Installation Drawing
o Instruction Manual
o Bill Of Materials (BOM) Manual
o Assembly Drawings
o (2 Sets) Wire Belt Connecting Master Links
o (5) Drain Screens
o (12) Main Cabinet Leveling Feet
o (4) Optional Add-On Single Dryer Module Leveling Feet
o (Set of 59 SST Bolts, Flats & Lock washers) Optional Add-On Single
Dryer Module Interface Hardware
o (12) Pads for Leveling Feet
o (4) Pads for Optional Add-On Single Dryer Module Leveling Feet
o (2 Sets) Optional CheckMate Conveyor Connecting Master Links
Figure 11 - System Documentation Package
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Installation Preparation 19
Aquastorm 200
SECTION 6 UNPACKING PROCEDURES(DOMESTIC SHIPMENTS ONLY)
Read this section in its entirety prior to
performing any unpacking procedures.
WARNING Heavy objects. Do not attempt tomove large assemblies without the useof a fork lift or other riggingequipment. Some large assemblies areextremely heavy and any attempt to
lift any assembly by hand will causepersonal injury.
5.1 INSTALLING THE SYSTEMLEVELING FEET
1 Wheel the Aquastorm 200 into placefor installation.
NOTE Do not remove any system
components from theircontainers prior to the
requirements of their
installation to prevent loss
of parts or installation
hardware.
2 Locate and open the cardboard containerlabeled "Documentation Package
Enclosed" then remove the system leveling
feet (quantity 12) from the container.
Figure 14 - Leveling Foot
Figure 13 - Leveling Feet in Documentation Package
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20 Installation Preparation
Aquastorm 200
CAUTION To avoid damage to the equipment
and system drain fixtures, do notplace fork lift forks at the positionsindicated by the CAUTION labels.
Adjust the fork lift forks to their widestposition. The Aquastorm 200 frame
width is 152cm (59.9 inches) wide.Use fork extensions on forks if theforks do not extend at least seven (7)feet.
3 Using a two (2) ton (4,000 lb.) minimumcapacity fork lift, carefully position the
extended forks at their widest setting
under the frame of the Aquastorm 200.
Do not to place the forks at the CAUTION
points.
4 Once the fork lift is in place, carefullyraise the system off the floor high enough
to remove the wheels and install the 12
leveling feet obtained in step two (2).
A 1 1/2" adjustable or fixed wrench is
required for the removal of the hardware
securing the wheels and for the
installation of the leveling feet.
5 Install the leveling feet so they extendapproximately 12.7cm (five {5} inches)
from the base of the system frame. Be
consistent with each leveling foot.
6 Remove the 12 Pads for the leveling feetfrom the cardboard container labeled
"Documentation Package Enclosed". Place
the pads below where each of the levelingfeet will rest on the floor at the site of
installation.
7 Carefully and slowly lower the Aquastorm200 onto the pads at the site of
installation. Remove the fork lift.
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Installation Preparation 21
Aquastorm 200
6.2 REMOVING THE SYSTEMPACKAGING MATERIALS
To ensure safe arrival to your facility, the
Aquastorm 200 and its components have been
carefully padded and secured. Remove the
packaging materials from the locations outlined
below.
CAUTION To prevent unnecessary damage to thecabinet's polypropylene surfaces, useextreme caution when cutting or
removing packaging materials so asnot to scratch or cut into thepolypropylene surfaces.
o Remove the plastic wrap from around the
perimeter of the system.
o Remove the Aquastorm 200 rear accesspanels to access the system tanks. Remove
the packaging tape securing the wash tank
lid, rinse tank lid, and optional chemical
isolation tank lid; reinstall the tank lids
and rear access panels.
Figure 16 - System with Protective Plastic Wrapping
Figure 17 - Tank Packaging
Remove the packagingfrom the tank area
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22 Installation Preparation
Aquastorm 200
Proceed to Section 7 "System Leveling".
o Remove the packaging tape securing the
sound enclosure lid and tool kit door.
o Remove the packaging tape and foam
padding from the optional spray wand in
the sink.
Figure 18 - Exit End Packaging
Figure 19 - Optional Sink Packaging
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Installation Preparation 23
Aquastorm 200
End Panel of Crate
SidePanelo
fCrate
End Panel of Crate
SidePanelof
Cr
Cut as indicated by the dotted lineafter adjusting the depth of the blade
Cut along opposite sidesand opposite ends
SECTION 7 CRATE DISMANTLING PROCEDURES(INTERNATIONAL SHIPMENTS ONLY)
Read this section in its entirety prior to
performing any dismantling procedures to prevent
damage to the equipment.
WARNING Heavy objects. Do not attempt tomove large assemblies without the useof a fork lift or other rigging
equipment. Some large assemblies areextremely heavy and any attempt tolift any assembly by hand will causepersonal injury.
1 Transport the Aquastorm 200 system
crate to the general vicinity of installationusing a three (3) ton (6,000 lb.) minimum
capacity fork lift.
CAUTION Take caution not to scratch or damagethe cabinet's polypropylene surfaceswhile dismantling the crate.
2 Using a circular saw with a rip cut bladeadjust the blade depth to approximate ly
2cm (3/4"). Carefully cut one (1) end
panel of the crate as illustrated by the
dotted line in the photograph below
approximately 20cm (8") from the top of
the crate. Repeat this step for the
opposite end of the crate.
3 Now adjust the depth of the circular sawblade to maximum depth.
4 Cut along the length (long side) of one (1)side of the top edge of the crate as
illustrated by the dotted line in
photograph #2, approximately 20cm (8")
from the top of the crate.
5 Now make an additional cut using thecircular saw along the length (long side) of
the opposite side of the top edge of the
crate approximately 20cm (8") from the
top of the crate.
Figure 20 - Crate Dismantling
Figure 21 - Crate Dismantling
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24 Installation Preparation
Aquastorm 200
6 The top of the crate should now be cut freefrom the crate. Carefully slide the top of
the crate off using several personnel or
with the aid of a fork lift. Do not drop the
trailing edge of the crate top, onto the top
of the system inside the crate.
7 Carefully remove any additional bracingfrom the inside of the top of the crate. Do
not damage the equipment.
8 Using pry bars and claw hammers removethe ends of the crate, then remove the
sides of the crate.
9 The entire Aquastorm 200 system hasbeen wrapped in moisture absorbent
plastic to prevent moisture damage to the
equipment during transit.
Remove the moisture absorbent plastic
from the system.
Figure 22 - Crate Opened
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Installation Preparation 25
Aquastorm 200
10 Cut and remove the strapping securing allcardboard containers and optional
components secured to the system skid.
11 Carefully remove all components cut freein step 10 and place them in a safe place
close to the site of installation for use in
installation procedures that follow in this
manual.
NOTE Do NOT open any cardboard containers until
directed by the procedures
in this manual.
12 The Aquastorm 200 system is mountedon 2 x 8" planks with foam shock pads,
then bolted to a wooden skid.
1-8 x 3" Bolts installed in existing leveling
foot locations in eight (8) locations (4 in
front; 4 at the rear), secure 16 metal
shipping plates to the underside of the
system frame. 1/2-13 x 8" Bolts are then
inserted through mounting holes in the
skid, through the foam pads, through the
planks, then through the mounting holes
on the shipping plates, and retained with
jam nuts to secure the system in place on
the skid.
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26 Installation Preparation
Aquastorm 200
Use a 3/4" socket wrench and ratchet to
remove the two (2) jam nuts from each of
the 16, 1/2-13 x 8" bolts from the
shipping plates.
CAUTION To avoid damage to the equipmentand system drain fixtures, do notplace fork lift forks at the positionsindicated by the CAUTION labels.
Adjust the fork lift forks to their widestposition. The Aquastorm 200 framewidth is 152cm (59.9 inches) wide.
Use fork extensions on forks if theforks do not extend at least seven (7)
feet.
13 Once all jam nuts have been removed fromthe 16 shipping plates, carefully position a
two (2) ton (4,000 lb.) minimum capacity
fork lift, with seven (7) foot (minimum)
fork extensions at their widest setting,
under the frame of the Aquastorm 200.
Do not position the forks at the
CAUTION points.
14 Once the fork lift is in place, carefullyraise the system off of the skid high
enough to remove the 16 shipping plates
and eight (8) 1-8 x 3" bolts securing them
to the system frame.
Use a 1 1/2"socket with ratchet to remove
the 1-8 x 3" bolts.
Proceed immediately to 6.1, Installing the
System Leveling Feet.
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Installation Preparation 27
Aquastorm 200
7.1 INSTALLING THE SYSTEMLEVELING FEET
1 Locate and open the cardboard containerlabeled "Documentation Package
Enclosed". Remove the system leveling
feet (quantity 12) from the container.
2 While the Aquastorm 200. system isstill elevated above the skid, install the 12
leveling feet obtained in step one (1), six
(6) in front and six (6) at rear of system.
3 Install the leveling feet so they extendapproximately 12.7cm (five {5} inches)
from the base of the system frame. Beconsistent with each leveling foot.
Figure 29 - Leveling Foot
Figure 28 - Documentation Package
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Aquastorm 200
28 Installation Setup
SECTION 8 INSTALLATION/SETUP
Read this section in its entirety prior to
performing any installation procedure.
WARNING All procedures outlined in this sectionare to be performed in the order inwhich they are presented. Failure to
do so may result in damage to theequipment or personal injury.
8.1 POSITIONING THEAQUASTORM 200
Carefully make the final adjustments positioning
the Aquastorm 200 using a forklift so that the
system will be in place for operation. The machinefront and back sides should be facing correctly
for required operation.
o Using the fork lift, carefully position the
Aquasto rm 200 into pl ac e for
installation.
o Remove the 12 Pads for the leveling feet
from the cardboard container labeled
"Documentation Package Enclosed". Place
them below where each of the leveling feet
will rest on the floor at the si te ofinstallation.
o Carefully and slowly, lower the Aquastorm
200 onto the pads at the site of
installation; then, remove the fork lift.
Once the system is properly positioned proceed
to the Main Cabinet Leveling Procedure.
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Aquastorm 200
Installation Setup 29
8.2 MAIN CABINETLEVELING PROCEDURE
1 On the "X" axis, place a level positionedon the underside corner of the Aquastorm
200 metal frame near the leveling foot.
2 Make the necessary height adjustments atthe base of the leveling foot hex head.
3 Turn the leveling foot hex head clockwiseto elevate the system or
counterclockwise to lower the system
until the distance between the base frame
of the cabinet and the floor is
approximately 10.16 cm (4 inches).
4 Repeat the above steps for all four (4)
corners of the system, front and rear.
5 On the "Y" axis, place the level positionedon the underside corner of the Aquastorm
200 frame near a leveling foot.
6 Make the necessary adjustments to theleveling feet to bring the system into
level.
7 Recheck the "X" axes to be sure theleveling at these points have not changed.
8 Repeat the above steps as necessary.
Base of Cabinet
Leveling FootHex Head
10.16 cm(4.0")
Twelve (12) Leveling Feet Locations Designated by this Symbol
Top View of Aquastorm 200
Y
X
Figure 31 - Leveling Foot Adjustment
Figure 32 -
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Aquastorm 200
30 Installation Setup
8.3 REMOVING THE SYSTEMPACKAGING MATERIALS
Now that the system is safely in place, the
packaging materials should be removed.
To ensure safe arrival to your facility, the
Aquastorm 200 has been carefully padded and
components secured by various means. Removethe packaging materials from the locations
outlined below.
CAUTION To prevent unnecessary damage to thecabinet's polypropylene surfaces, useextreme caution when cuttingstrapping or removing packagingmaterials so as not to scratch or cutinto the polypropylene surfaces.
o Remove the plastic wrap from around the
perimeter of the system.
Figure 33 - Removing the plastic wrap
Figure 34 - Removing the foam padding from the windows
o Remove the foam padding from the
windows and packaging tape from the
surfaces of the cabinet.
o If your system is configured with the
optional Inlet Conveyor, remove any
strapping and padding securing the
turnbuckles to the entrance end of the
cabinet. Carefully set the unsecured ends
of the turnbuckles on the floor until the
time of installation of the Inlet Conveyor.
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Aquastorm 200
Installation Setup 31
o Remove the Aqustorm 200 rear access
panels to access the system tanks. Remove
the packaging tape securing the wash tank
lid, rinse tank lid, and optional chemical
isolation tank lid; reinstall the tank lids
and rear access panels.
o Remove packaging tape securing the
sound enclosure lid and tool kit door.
o Remove the packaging tape and foam
padding from the optional spray wand in
the sink.
Fgure 35 - Tank Packaging
Remove the packagingfrom the tank area
Fgure 36 - Sound Enclosure and Tool Kit Door Packaging
Fgure 37 - Optional Sink Packaging
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Aquastorm 200
32 Installation Setup
8.4 INSTALLING THE DRAINSCREENS
The Aquastorm 200 has five (5) drain screens.
Two (2) in the prewash section; and one (1) in
each of the following tanks: wash, rinse, and
optional chemical isolation.
Refer to the illustration below for properinstallation of the drain screens.
1 Locate and remove the drain screens fromthe contents of the cardboard container
labeled "DOCUMENTATION
PACKAGE ENCLOSED".
2 Install the two (2) prewash drain screensfrom the front of the prewash section.
Open the front window, then remove the
prewash splash shield; install one (1)
drain screen over the prewash cascade
drain (the drain closest to the front of
the system), and one over the prewash
drain.
3 Go to the rear of the system and removethe rear access panels.
Remove the rear access panels starting
with the panel closest to the entrance
end.
4 Remove each of the tank covers from theirrespective tanks.
5 Install a drain screen in the bottom ofeach of the tanks.
6 Replace the tank covers on each of therespective tanks
Figure - 39 Drain Screen
Fgure 38 - Documentation Package
Install 2 Drain Screens in thePrewash section via the FrontWindow
Install a Drain Screen in the Wash,Rinse, and Optional Chemical Isolation
tanks from the rear of the system
Figure 40 - Prewash Drain Screen Location
Figure 41 - Tank Drain Screen Locations
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Aquastorm 200
Installation Setup 33
8.5 OPTIONAL SUMPPUMP INSTALLATION
Materials Required
610 cm (20 ') Maximum length of 11/
2" CPVC
drain pipe
Lengths of 1" facility drain pipe
Teflon
TapeCPVC Cement and Solvent
Tools Required
Channel lock pliers
Pipe wrench
NOTE Waste water d ischarge
solutions from the
Aquastorm 200 may be
regulated by local, county,
state or federal agencies.
Indiscriminate discharge is
not recommended.
Contact a local governing
agency for proper permits,
discharge requirements
and pretreatment
conditioning prior to
operating the Aquastorm
200.
Sump Pump
Refer to Figure 42 on page 34 labeled "Sump
Pump Installation" for steps 1 - 8 of this
procedure.
1 If your system has been configured withthe Optional Sump Pump, locate and
remove the assembly from the shipment
contents.
NOTE The Optional Sump Pump
assembly is configured
with the necessary
electrical connectors and
610 cm (20 ') of cable
Additional plumbing
required for site
installation is customersupplied; 1 1/2" CPVC
drain plumbing; 1" facility
drain plumbing. Be sure to
use Teflon tape on al
threaded plumbing
fittings. The Sump
assembly is designed to be
positioned at the exit end
of the Aquastorm 200
system.
2 Position the sump pump assembly at theexit end of the system, with the drain pipe
facing the exit end of the system.
3 Install a union or coupling (customersupplied) at the end of the 1
1/
2" drain
plumbing at the exit end of the Aquastorm
200 system.
4 Install the required length of 1 1/2" CPVC
drain pipe (not to exceed 610 cm {20 '})to the remaining end of the union or
coupling.
5 Connect the opposite end of the drain pipeinstalled in step 4 to the 1
1/2" NPTF
fitting on the sump.
6 Connect the 1.0" NPTF sump outlet tothe facility 1.0" (customer supplied) drain
or facility water treatment system.
7 Locate the cable from the sump pump withthe connector labeled PG27.
8 Plug the connector labeled PG27 into thereceptacle at the exit end of the
Aquastorm 200 labeled PG27.
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Aquastorm 200
34 Installation Setup
ConnectSumpInlet(11/2"NPTF)
toAquastorm200's
standard11/2"NPTM,drain
attheexitendofthecabinet
11/2"CPVC
drainfromsystemtoSump
(CustomerSupplied)
ConnectSumpOutletto
1.0"NPTFFacilityDrain
(CustomerSuppliedplumbing)
SumpOutlet
1.0"NPTF
SumpS
ideView
ConnectPlug#PG27from
SumpintoSumpreceptacle
at
exitendofcabinetlabeled
PG27
Receptacle
InstallaUnion
orcouplingHere
Connector
Cable
SumpPumpInstallation
Figure4
2-
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Aquastorm 200
Installation Setup 35
8.6 OPTIONAL TREATMENTINTERFACE INSTALLATION
Materials Required
457 cm (15 ') Maximum length of 11/2" CPVC
drain pipe
Lengths of 1" CPVC, schedule 80 facility
drain pipeLengths of 3/4" CPVC, schedule 80 fill pipe
Teflon Tape
Tools Required
Channel lock pliers
Pipe wrench
NOTE Waste water discharge
solutions from the
Aquastorm 200 may be
regulated by local, county,
state or federal agencies.
Indiscriminate discharge is
not recommended.
Contact a local governing
agency for proper permits,
discharge requirements
and pretreatment
conditioning prior to
operating the Aquastorm
200.
Treatment Interface System
Refer to Figure 43 on page 36 labeled "Treatment
Interface Installation" for steps 1 - 10 of this
procedure.
1 If your system has been configured withthe Optional Treatment Interface, locate
and remove the assembly from the
shipment contents.
NOTE The Optional Treatment
Interface assembly is
configured with the
necessary electrical
connectors and 610 cm
(20 ') of cable. Additional
plumbing required for
site installation is
customer supplied; 1 1/2"
CPVC drain plumbing;
1" faciltiy drain
plumbing, and 3/4" fill
plumbing. Be sure to use
Teflon tape on all
threaded plumbing
fittings. The Treatment
Interface assembly is
designed to be positioned
at the exit end of the
Aquastorm 200
system.
2 Position the treatment interface assemblyat the exit end of the system, with the
drain pipe facing the exit end of the
Aquastorm 200 system.
3 Install a union or coupling (customersupplied) at the end of the 1
1/
2" drain
plumbing at the exit end of the Aquastorm
200 system.
4 Install the required length of 11/2" CPVC
drain pipe (not to exceed 457 cm {15 '})
to the remaining end of the union or
coupling.
5 Connect the opposite end of the drain pipeinstalled in step 4 to the 1 1/2" NPTFfitting on the inlet side of the treatment
interface.
6 Connect the 1.0" NPTF treatmentinterface outlet to the optional CLS 1.0"
inlet (See CLS installation manual for
CLS fitting locations), using the customer
supplied 1.0" plumbing.
7 Connect the 3/4" fill line from the
Aquastorm 200 to the
3
/4" NPTF fittingon the treatment interface using the
customer suppplied3/
4" plumbing.
8 Connect the treatment interface 11/2
drain overflow to facility drain, or to the
optional sump pump's 11/
2" inlet side
drain plumbing. This connection is for
high level overflow only.
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Aquastorm 200
36 Installation Setup
TreatmentTankSideView
ConnectPlug#PG26fromthe
Treatmentsystemintothereceptacle
atexitendofcabinetlabeledPG26
Receptacle
DrainOverflow
11/2"NPTF
InletFrom
AquastormDrain
11/2"NPTF
FillFrom
Aquastorm
3/4"NPTF
Outletto
CLS1"NPTF
Pump
OutlettoCLS1"NPTF
InletFrom
AquastormDrain
11/2"NPTF
DrainOverflow
11/2"N
PTF
System11/2"
DraintoOptional
SumporFacility
Drain
InstallCouplingHere
ConnectorCable
Figure43TreatmentInterfaceInstallation
9 Locate the cable from the treatmentinterface with the connector labeled
PG26.
10 Plug the PG26 connector into thereceptacle at the exit end of the
Aquastorm 200 labeled PG26.
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Aquastorm 200
Installation Setup 37
8.7 OPTIONAL INLETCONVEYOR EXTENSIONINSTALLATION
Tools Required -
8 mm Box Wrench
13 mm Box Wrench
5 mm Allen Wrench
Refer to Figure 44 - Inlet Conveyor Installation
on page 38 for the assembly instructions which
follow.
1 Locate and remove the Adjustable InletConveyor Extension and mounting
hardware from the contents of the crate.
2 Using a 13 mm box wrench, remove thehardware, (2-9200-051-00-0, hex head
bolts, 2-9232-007-00-0, flat washers, 2-9233-005-00-0, lock washers) from
either end of the Idler Shaft Assembly to
allow removal of the idler shaft assembly
and spacers (525778-01) from the
conveyor extension.
NOTE Take caution not to lose
the Teflon spacers
(525778-01) at either
side of the inlet conveyor,
since they need to bereinstalled.
Do Not disassemble the
Idler Shaft Assembly.
3 Carefully, lift the inlet conveyor assembly.Install the end of the inlet conveyor, in
which the shaft assembly was removed,
into the entrance end mounting bracket
(3-0077-114-01-6). The bracket is
already installed on the Aquastorm 200cabinet. Utilize the vertical slotted
mounting hole for installation (refer to
Figure 43 - Inlet Conveyor Installation on
page 37).
4 Install the spacers (525778-01), quantityone (1) at either side of the inlet conveyor,
between the inlet conveyor and entrance
end mounting bracket.
5 While hold ing the spacers in placeposition the idler shaft assembly removed
in step 2. Align the mounting holes, then
install the hardware removed in step 2, (2
9200-051-00-0, hex head bolts, 2-9232
007-00-0, flat washers, 2-9233-005-00
0, lock washers) at either side of the inleconveyor.
Finger tighten the hex bolts at this time
so that angle adjustment may be made
DO NOT TIGHTEN SECURELY.
6 Locate the left (512779-01)and right(512778-01) threaded height adjustment
rods and turnbuckles (512780-01) that
were already installed on the system prior
to shipment.
Using a 5 mm Allen wrench and an 8 mm
box wrench, remove the shoulder screws
(2-9290-011-00-0) and hex nuts (2
9237-004-00-0) from the top ends of the
left hand threaded adjustment rods
(512779-01).
7 Align the holes in the ends of the left handthreaded adjustment rods (512779-01
with the mounting holes in the side panels
(3-0787-220-01-6) of the inlet conveyor.
8 Install the hardware removed in step 6through the threaded adjustment rods, to
the side panels of the inlet conveyor with
the heads of the shoulder bolts facing out
and the double hex nuts on the inside of
the inlet conveyor.
Tighten the hardware securely using a
5 mm Allen wrench and a 5 mm box
wrench.
9 Adjust the height of the Inlet ConveyorExtension to the required position by
turning the turnbuckles.
10 Once the inlet conveyor has been adjustedto the required operating position, use a
13 mm box wrench to tighten the
hardware which was finger tightened in
step 5.
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Aquastorm 200
38 Installation Setup
2-9
200
-051
-00
-0
M8x
40SSTHex
Hea
dBo
lt
2
-9233
-005
-00
-0
M8SSTSp
litLoc
kWasher
2-9
232
-007
-00
-0
M8SSTFlatWasher
Idler
Sha
ftAssem
bly
3-0
077
-114
-01-6
Conveyor
Bracke
t
525778
-01
Spacer
2-9
290
-011
-00-0
8x
M6x
20Socke
t
Hea
dShou
lder
Bolt
2
-9237
-004
-00
-0
M5SSTHex
Nu
t
Idler
Sha
ftAssem
bly
512780
-01
Leftan
dRightTurn
buc
kles
512778
-01
RightThrea
de
d
He
ightAdjust
Ro
d
512779
-01
Left
Threa
de
d
He
igh
tAdjust
Ro
d
3-0
787
-220
-01
-6
Side
Plate
Figure44-
InletConveyorInstallation
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Aquastorm 200
Installation Setup 39
8.8 OPTIONAL PHOTOCELLHOOK-UP
The optional photocell emitter and mounting
hardware are removed from the inlet conveyor
prior to shipment on crated shipments.
Locate the mounting hardware and photocell
components packaged at the entrance end of theAquastorm 200.
Align the mounting holes of the photocell
mounting bracket (p/n 523977-01) with the
slotted holes as depicted in the illustration below,
on the right hand side of the inlet conveyor, facing
the entrance end of the system.
Using the M 5 hardware illustrated in the diagram
Detail "A"
Detail "A"
M 5 Pan Head Bolt2-9210-030-00-0 ( QTY 2)
M 5 Lock Washer2-9233-003-00-0 (QTY 2)
M 5 Flat Washer2-9232-022-00-0 (QTY 4)
M 5 Hex Nut2-9237-004-00-0 (QTY 2)
Photocell Mounting Bracket523977-01
below, insert the pan head bolts with flat washers
through the slotted holes on the inside of the
inlet conveyor through the mounting holes of the
photocell mounting bracket.
Install the M 5 lock (2-9233-003-00-0)and M 5
flat (2-9232-022-00-0) washers on the back side
of the bolt (2-9210-030-00-0) , then secure withthe M 5 hex nut (2-9237-004-00-0).
NOTE Befo re opera ti ng the
photocell, perform the
Photocell Alignmen
procedure on page 2-14 of
the Instruction Manual.
Figure 45 - Photocell Mounting
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Aquastorm 200
40 Installation Setup
8.9 BOLT ON SOUNDENCLOSURE INSTALLATION(Crated Shipments Only)
The sound enclosure is designed for removal prior
to shipping for those shipments which are to be
crated.
For shipments that are received crated, performthis installation procedure.
Refer to Figure 63 below for the installation of
the sound enclosure.
1 The Sound Enclosure is to be installedusing M6 metric hardware. Locate the 24
sets of M6 hardware inside the box labeled
"Documentation Package".
CAUTION Heavy Object - The exit end soundenclosure is heavy. Arrange for three
(3) or four (4) personnel to lift it intoposition, or use the appropriaterigging equipment to position the
sound enclosure for installation.
2 Position the sound enclosure at the exitend of the Aquastorm 200 system
cabinet as illustrated in Figure 63.
3 Install two (2) M6 x 40 hex head bolts (2-9200-035-00-0) with M6 flat washers (2-
9232-023-00-0) into the two (2) upper
most corner mounting holes, from the
inside of the sound enclosure.
Use these two (2) holes to align the soundenclosure to the Aquastorm's exit end
bulkhead mounting holes.M6 Flat Washer
2-9232-023-00-0
M6 x 40 Hex Head Bolt2-9200-035-00-0
Bolt Thru Exit Bulkhead andExit Enclosure (24 sets of hardware)
M6 Flat Washer2-9232-023-00-0
M6 Hex Nut2-9237-005-00-0
M6 Lockwasher2-9233-004-00-0
Sound EnclosureBulkhead shownBlown out fromAssembly to showMounting hole Locations
Sound Enclosure
Close-Up Cut-Away View ofMounting Hardware Configuration
Sound EnclosureBulkhead
Aquastorm 200Exit End Bulkhead
Figure 63 - Sound Enclosure Installation
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Aquastorm 200
Installation Setup 41
4 Secure the two (2) sets of hardwareinstalled in step 3, by installing an M6 flat
washer (2-9232-023-00-0), M6 lock
washer (2-9233-004-00-0), and an M6
hex nut (2-9237-005-00-0) on the bolts
from the inside of the Aquastorm's exit
end of the cabinet. DO NOT tighten
completely until all additional mounting
hardware has been completely installed.
5 Install all remaining, 22 sets, of hardwarein the mounting holes illustrated in Figure
63 on page 40, then tighten securely.
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Aquastorm 200
42 Installation Setup
8.10 CONVEYOR WIRE BELTINSTALLATION(CRATED SHIPMENTS ONLY)
When the Aquastorm 200 is shipped crated,
the Optional Inlet conveyor extension and the
conveyor wire belt are removed for shipment.
Perform this procedure if your system was
received as a crated shipment with the Optional
Inlet conveyor extension.
NOTE If your system is not
configured with the
Optional Inlet ConveyorExtension, the conveyor
wire belt is not removed
from the system for
shipment, therefore it is
not necessary to perform
this procedure.
1 Locate and remove the roll of ConveyorWire Belt from the contents of the
shipment.
2 Bring the roll of wire belt to the exit endof the Aquastorm 200.
3 Arrange the wire belt so the Closed End of
the Hook Loops are facing towards the
EXIT end of the Aquastorm 200.
Open Side of LoopFacing Toward
Entrance End
Closed Loop SideToward Exit End
Feeding the Wire Belt
Entrance End Exit End
Feed the Wire Belt from the top of the cotoward the exit end of the system, then athe underside of the conveyor, toward theend of the Optional Inlet Conveyor assemb
Figure 46 - Wire Belt Installation
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Aquastorm 200
Installation Setup 43
Feeding the Wire Belt
Feed the Wire Belt from the top of the conveyortoward the exit end of the system, then around
the underside of the conveyor, toward the entranceend of the optional Inlet Conveyor assembly.
Feed over Top
Pull from Bottom
4 Manually feed the wire belt from theentrance end of the cabinet through the
TOP PORTION of the conveyor first.
5 Pull the wire belt all the way through thesystem to the exit end of the conveyor.
Pull the wire belt through the system by
reaching inside the window port of eachstage and pulling the wire belt through.
6 Bring the wire belt around to the bottomof the exit end of the conveyor, so that it
hangs approximately 15.24cm (6 inches)
over the end.
7 Go to the entrance end at the OptionalInlet Conveyor and feed the remaining
portion of the wire belt through the
system, leaving enough wire belt to extend
to the middle of the inlet conveyor.
Assist pulling the wire belt from the exit
end of the conveyor, and by reaching
inside the window port of each stage an