Akron brass 3406 User manual

STYLE 3406 ELECTRIC RISER

The following is intended to provide the basic instructions for installation, operation and maintenance of the Electric

Riser, and to assist in attaining the best possible performance from the unit. Read and understand these operating

instructions before use.

TOOLS REQUIRED

• UtilityKnife • Mediumatscrewdriver

• MediumPhillipsscrewdriver • Smallatscrewdriver

• SmallPhillipsscrewdriver • 3/4inchhexheadwrench

• Deutschcrimptool(P/NHDT-48-00)

• Electrician’spliers(multipurpose,strippingandcrimping)

PRODUCT RATINGS

MaximumMotorCurrentDraw:

12 volt versions 22 amps

24voltversions 11amps

NormalOperatingCurrent:(Dependingonoperatingconditions–pressure,ow,etc.)

12 volt versions 17 amps

24voltversions 8.5amps

MinimumVoltage:(Truck engine must be operating for proper voltage requirement.)

All12voltmotors:11.5voltswhileoperating

All24voltmotors:23voltswhileoperating

MaximumFlow:1250gpm(4800lpm)

MaximumPressure:250psi(17 bar)

PRODUCT WARNINGS

WARNING: Forreghtinguseonlybytrainedreghters.

WARNING: Chargetheunitslowly.Rapidchargingmaycauseapressuresurgethathasthepotentialtocausean

injury,ordamageriserand/orthemonitor.

WARNING: DONOTstowordeploytheRiser/Monitorwhileowing.Pressingthestowordeploy

buttonscausesthenozzletomoveautomaticallyandthewaterstreammaycausedamagetoequipment

orinjurytopersonnel.

WARNING: Aimtheunitinasafedirectionbeforepumpingwaterthroughit.(e.g.awayfrompowerlines)

WARNING: Althoughthelogiccircuitboardincludesawater-resistantcoating,itisimportanttokeepwateroutof

thecontrolboxandlogicbox.Prolongedexposuretowaterwillcausedamage.Whenthecoverofthe

controlboxorlogicboxisremoved,checkthatthegasketunderthecoverisintactandfreeofdirtand

debris.

WARNING: Donotusetheelectriccontrolswhentheoverridecranksarebeingusedorareinpositionforuse.

WARNING: Maketheconnectionofthevehiclebatterythenalstep.

WARNING: Replacetheidenticationtagsiftheyshouldbecomewornordamaged.

WARNING: DONOTexceedthemaximumpressureorowratingsoftheriser.Exceedingtheseratingsmaylead

toaninjuryormaycausedamagetothemonitor.

WARNING: DONOTinstallshutoffsontheoutletoftheelectricmonitor.Shutoffsincreasethepotential

forpressuresurgesduetowaterhammer,whichhavethepotentialtocauseaninjuryordamagethe

riserand/ormonitor.

WARNING: Risermayextendifwaterpressureisappliedpriortodeployingtheassembly.

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WARNING: Ifnotequippedwithanautomaticdrainvalve,draintheRiserafterusetoprevent“freeze

damage”.

MECHANICAL ATTACHMENT OF ELECTRIC RISER TO MONITOR

WARNING: INSUFFICIENTSTRUCTURALSUPPORTCANLEADTOFAILURE,WHICHHASPOTENTIALTOCAUSE

ANINJURY.THEREFORE,ADDITIONALSTRUCTURALSUPPORTATTHEINLETFLANGEORATTHE

INLETELBOWMAYBEREQUIRED.

ThemonitoristobemountedtotheMonitorSupportFlangewithfour5/8”boltsandnutsofgradeve

minimumandsuitablewasherswithaminimumofsixthreadsengagement.Thenotchthatiscutintotheinletangeis

thefrontofthemonitor.Theboltsmustbetightenedinacriss-crosspatternprogressivelyincreasingtighteningtorqueto

amaximumof100lb.ft.dry.(SeeFigure3.)

EXTENSION STOPS

Theextensionstopssettheboundariesfortheheightthattheriserisallowedtotravel.Thesestopsshouldnotbe

removedoradjustedforanyreason.

MECHANICAL ATTACHMENT OF ELECTRIC RISER TO APPARATUS

TheElectricriserisattachedtotheapparatususingfour1/2-13boltsofgradeveorhigher.Thelengthofthebolts

shouldbe2-1/2”plusthethicknessofthemountingsurface.(SeeFigure3.)

MECHANICAL ATTACHMENT OF MINI UNIVERSAL CONTROLLER TO ELECTRIC RISER

Theminiuniversalcontrollermountstotheelectricriserwiththetwo1/4-20x1"capscrewsandwashersprovided.

(SeeFigure3.)

ELECTRICAL INSTALLATION INSTRUCTIONS

DeckMaster with Prox Switches (No Position Feedback & Universal 1 Logic Box)

A. Connect Mini Universal Controller to Universal 1 Logic Box

(1) Determinethelengthofcable(18AWG,6conductor)neededbetweentheMiniUniversalControllerandthe

DeckMasterlogicbox.Addanadditional6”tothemeasuredlength.Installthesuppliedcordgripintothe

DeckMasterlogicbox.Removethecordgripnutandslideontothecable.Removethecordgripbushing

and compression grommet and slide them onto the cable.

(2) Strip6”ofthejacketoffoftheDeckMasterlogicboxsideofthecableandthreadthecablethroughthe

cordgripbodyonthelogicbox.RoutethecabletotheTB3terminalstriparea.Slidethecompression

grommetandbushingintothecordgripbody.Slidethecordgripnutuptothecordgripbodyandtighten

until the cord is secured.

(3) RefertoFigure2fortheelectricalconnectionbetweentheDeckMasterlogicboxandtheMiniUniversal

Controllerconnectors.ThewiringdiagramontheDeckMasterlogicboxlidcanalsobeused

as a reference.

B. Set the Option (DIP) Switches on the Universal 1 circuit board inside the 3440 DeckMaster logic box

(1) Theswitchesarefactorysetat:

(2) Setswitch#4totheUPposition.ThiswillallowtheRiserandtheDeckMastertobeautomaticallycoor-

   dinatedduringdeployingandstowing.WARNING: If switch #4 is down and the DEPLOY or STOW

switch is pressed, damage may occur from the monitor hitting an obstacle due to the fact that the

Riser will not extend or retract.

12345678

UP(ON) • • •

DOWN(OFF) • • • • •

1 2 3 4 5 6 78

UP(ON) • • • •

DOWN(OFF) • • • •

DeckMaster with Position Feedback, All StreamMasters (Universal 1 Logic Box)

Note:ThesoftwarefortheDeckMasterwithPositionFeedbackandalloftheStreamMastersdoesnotsupportthe

ElectricRiser.TheElectricRisermustbeusedinstand-alonemodewithitsowndedicated“Extend/Retract”

toggle switch.

A. Connect an EXTEND/RETRACT toggle switch to the 6033 Mini Universal Controller

(1)UseanSPDTmomentarystyletoggleswitchwherethecenterpositionisoff.

(2)ConnecttheswitchCOMMONterminaltotheblackconnector(righthandsideof6033),positionnumber1.

(3)ConnecttheswitchRETRACTterminaltotheblackconnector,positionnumber2.

(4)ConnecttheswitchEXTENDterminaltotheblackconnector,positionnumber3.

B. Connect power to the DTP04-2P receptacle connector on the 6033 Mini Universal Controller

• 12AWGRedWireis+SystemVoltage(12or24VoltsDC)

• 12AWGBlackWireisSystemGround

• Useappropriatefuseorcircuitbreakertoprotectwiring

• Thevoltageratingonthemotormustmatchthesystemvoltage.

C. Optionally connect the Retracted/Extended Indicator Relays on the 6033 Mini Universal Controller

• FullyRetractedRelay:ThisrelayturnsonwhentheRiserisFULLYRETRACTED.Also,theK1-GREENLED

(Middlefrontof6033)willturnon.Thedryrelaycontactsarelocatedatpositions9and10ofthegray

connector(leftsideof6033),andareratedat1ampmaximum@30VDC.

• FullyExtendedRelay:ThisrelayturnsonwhentheRiserisFULLYEXTENDED.Also,theK2-REDLED(Middle

frontof6033)willturnon.Thedryrelaycontactsarelocatedatpositions11and12ofthegrayconnector(left

sideof6033),andareratedat1ampmaximum@30VDC.

Universal II Logic Box

A. Connect to CAN network using AB cable #721594.

B. Follow the set VP procedure for the monitor that you are using.

C. Enable the Electric Riser in the set-up menu.

• ErrorCode2-1indicatesthattheriserfunctionisenabled,buttheriserisnotavailableonthenetwork.

OPERATING INSTRUCTIONS

WARNING: Be sure to completely deploy the Riser/Monitor before ﬂowing water.

DeckMaster with Prox Switches (No Position Feedback) – “Automatic Mode”

• Deploy:LiftthesafetycoverontheDEPLOY/STOWswitch,pushthetoggleswitchupandthenrelease.The

RiserwillextendtolifttheDeckMasterup12”andthentheDeckMasterwilldeploy.

• Stow:LiftthesafetycoverontheDEPLOY/STOWswitch,pushthetoggleswitchdownandthenrelease.

TheDeckMasterwillstowandthentheRiserwillretract.

• EmergencyStopduringDeployorStow:IfitisnecessarytoimmediatelystoptheRiser/DeckMasterduring

thedeployorstowsequence,activateanyswitchonthecontrolpanelandtheunitwillstopmoving(E-Stop).

Tocompletethedeployorstowsequenceafteranemergencystop,presstheDEPLOYorSTOW

switch again.

DeckMaster with Position Feedback, All StreamMasters – “Stand-Alone Mode”

• Deploy:PressandholdtheEXTENDswitchuntiltheRiserisfullyextended,andthenreleasetheEXTEND

switch.LiftthesafetycoverontheDEPLOY/STOWswitch,pushthetoggleswitchupandthenrelease.The

monitorwilldeploy.

• Stow:LiftthesafetycoverontheDEPLOY/STOWswitch,pushthetoggleswitchdownandthenrelease.

Themonitorwillstow.PressandholdtheRETRACTswitchuntiltheRiserisfullyretracted,andthenrelease

theRETRACTswitch.

• EmergencyStopduringDeployorStow:IfitisnecessarytoimmediatelystoptheMonitorduringthedeploy

orstowsequence,activateanyswitchonthecontrolpanel(exceptEXTEND/RETRACT)andtheunitwillstop

moving(E-Stop).Tocompletethedeployorstowsequenceafteranemergencystop,presstheDEPLOYor

STOWswitchagain.

Manual Override Control: Themanualoverrideistobeused,onlywhenthepowertotheRiserisoff.Toraisethe

Riser,apply50PSIofwaterpressureanditwillgoup.Tolower,turnoffwater,pullthepinatthetopofthe

actuator and lower monitor and riser.

Note: Youwillhavethefullweightoftheriserandmonitor.Itwouldbebesttousemorethanoneperson.

Itwillalsohelptolifetthemonitorandriserasyoupullthepin.

6.05

2.95

4.00

4.63

Ø .29

1/4-20 X 1” FASTENER

(2 PLACES)

123456

7 8 9 10 1112

12 1110 9 8 7

1 2 3 4 5 6

Front

Gray

Power Motor

Black

Figure 1

Troubleshooting Tips for the 6033 Mini Universal Controller

(1) Openfusedetection(monitoredcontinuously).

(2) Motordisconnected,oropenmotorcircuitdetection(checkedonceeverytimemotoristurnedon).Wheneither

oftheseconditionsarefound,theMiniUniversalwill:

• Stoptryingtorunthemotor

• TurnoffinputcommandindicatorsLED1orLED6

• TurnOFFRelayK1(GreenLED=Retracted)

• TurnOFFRelayK2(RedLED=Extended)

• TurnonFAULTindicatorLED3

• Remaininthisconditionuntilfaultiscleared/xed,ANDpoweristurnedoff,thenbackon

(3) LED1andLED6areinputsignalcommandindicators.Theyshouldcomeonwhenthe6033MiniUniversal

ControllerisbeingtoldtoExtend,ortoRetract.

(4) The“POWEROUT”LEDatthetoprightsideofthe6033comeson Green when power is being sent out to the

Electric Riser motor to RETRACTthe3406Riser.

(5) The“POWEROUT”LEDatthetoprightsideofthe6033comesonRed when power is being sent out to the

Electric Riser motor to EXTENDthe3406Riser.

MAINTENANCE INSTRUCTIONS

Theelectricrisershouldbeinspectedpriortoandaftereachusetoensureitisingoodoperatingcondition.Periodically,

an unanticipated incident occurs where the unit is used in a manner that is inconsistent with standard operating prac-

tices.Apartiallistoftheseusesincludes:

• Operatingabovethemaximumratedpressureorow.

• Prolongedexposuretotemperaturesabove130°F,orbelow-25°F.

• Operatinginacorrosiveenvironment.

• Havingthemonitornozzlehitaxedobjectduringoperationortransportation.

• Anymisusethatmightbeuniquetoyourspecicenvironment.

Also,therearemany“telltale”signsthatindicaterepairisinorder,suchas:

• Controlsthatareeitherinoperableordifculttooperate.

• Excessivewear

• Poordischargeperformance

• Waterleaks.

Ifanyoftheabovesituationsareencountered,theRiser/Monitormonitorshouldbetakenoutofservice,repaired,and

testedbyaqualiedtechnicianbeforeplacingbackinservice.Greasettingsareprovidedabovetheextensionstops.

Tolubricatetheriser,placeitintheextendedpositionandwipeoffanyoldgreaseresiduefromthetubes.Usinga

manualgreasegun,applytwoshotsofgreasetoeachtting.

MINIUNIVERSALCONTROLLER

Figure 2

MASTER

SLAVE

TB1

TB3

28 15

BLACK 12 POSITION CONNECTOR

GRAY 12 POSITION CONNECTOR

Factory Settings

DOWN

Return to Stream During Stow

Jog to Stow or Deploy

Use with Electric Riser

Enable LEARN Mode

DOWN

Enable Timer for Elev. Arm Stow

Stow Nozzle in Cradle

Operate in Stowed Position

Stow Only at HOME Position

FACTORY USE ONLY

RUN MODE

DTP04-2P

DTP06-2S

BLUE AND WHITE WIRES

RED AND BLACK WIRES

Notes:

3440 DECKMASTER WITH PROX SWITCHES (NO POSITION FEEDBACK)

- GRAY LOGIC BOX

SEE LID LABEL INSIDE LOGIC BOX FOR ADDITIONAL

1 - DIP Switch 4 must be in the UP position for Electric Riser to operate.

2 - Software version of the 3440 board must be between Version 8 & Version 19.

Older versions (e.g. vers7) will not "tell" Riser to Extend or Retract.

3 - After "LEARNING" new Deploy, or Stow positions, place DIP Switch 8

in the DOWN position. This will lock in the new position.

WIRING INFORMATION

4 - Verify that there is a jumper wire from terminal TB3-3 to TB3-18 and

another one from terminal TB3-3 to TB3-21. The Riser will not operate

if these two jumpers are missing.

6033 Mini Universal

DIP SWITCH FUNCTIONS ARE ACTIVE ONLY WHEN

THE SWITCH IS IN THE UP ("OPEN") POSITION

NOTE:

UP = FUNCTION ACTIVE (SWITCH OPEN)

FROM ELECTRIC

MOTOR ON THE

3406 ELECTRIC RISER

CUSTOMER SUPPLIED

WIRING - POWER FROM

BATTERY

Position 1 = POSITIVE BAT.

Position 2 = NEGATIVE, GND.

1 - RED

2 - BLACK

30-1/2

8.115 9.000

10.841

7-57/64

13-31/32

6-5/32

4-1/4

6.500 5.500

10.841

.531

18-1/2

9-55/64

11/16 ON A

6.000 B.C.

RISER IN RETRACTED

POSITION RISER IN EXTENDED

POSITION

MINI UNIVERSAL

CONTROLLER

MONITOR

SUPPORT

FLANGE

MINI UNIVERSAL

CONTROLLER

BOLT HOLES FOR

MECHANICAL ATTACHMENT

OF ELECTRICAL RISER

TO APPARATUS

MONITOR SUPPORT FLANGE

MINI UNIVERSAL

CONTROLLER

1/4-20 X 1”

MOUNTING BOLTS

MONITOR OVERRIDE PIN

MONITOR

OVERRIDE

Figure 2Figure 3

NOTES:

________________________________________________________________________

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PHONE: 330.264.5678 or 800.228.1161 I FAX: 330.264.2944 or 800.531.7335 I akronbrass.com

WARRANTY AND DISCLAIMER: We warrant Akron Brass products for a period of ﬁve (5) years after purchase against defects in materials or workmanship. Akron Brass will repair or replace product

which fails to satisfy this warranty. Repair or replacement shall be at the discretion of Akron Brass. Products must be promptly returned to Akron Brass for warranty service.

We will not be responsible for: wear and tear; any improper installation, use, maintenance or storage; negligence of the owner or user; repair or modiﬁcation after delivery; damage; failure to follow

our instructions or recommendations; or anything else beyond our control. WE MAKE NO WARRANTIES, EXPRESS OR IMPLIED, OTHER THAN THOSE INCLUDED IN THIS WARRANTY STATEMENT,

AND WE DISCLAIM ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. Further, we will not be responsible for any consequential, incidental or