CD3 Station User manual

CD3 PRODUCTS MANUAL
RevA-28MAR20

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CD3 Products Manual
CD3, General Benefit Corporation | www.cd3station.com | [e-mail] | 612.467.9441
Patent Pending | Made in USA | © 2019
3
Table of Contents
Section 1 –General Unit Overview ......................................................................................... 6
1.1 Unit Model Descriptions......................................................................................................6
1.1.1 Station .........................................................................................................................................................6
1.1.2 Wayside 120V .............................................................................................................................................6
1.1.3 Wayside Solar..............................................................................................................................................6
1.1.4 Outpost .......................................................................................................................................................7
1.1.5 Trailer Option (Wayside 120V and Wayside Solar Only) .............................................................................7
1.2 Unit Layouts and Features........................................................................................................8
1.2.1 Overview Station/Wayside - Front..............................................................................................................8
1.2.2 Overview- Station/Wayside - Rear..............................................................................................................9
1.2.3 Overview –Outpost ..................................................................................................................................10
1.3 Unit General Specifications ....................................................................................................11
Section 2 –Before Operation ............................................................................................... 12
2.1 Installation ............................................................................................................................12
2.1.1 Stationary Mounting .................................................................................................................................12
2.1.2 Electrical Install (Station, Wayside 120V)..................................................................................................13
2.2 Safety Information.................................................................................................................15
Section 3 –Unit Operation................................................................................................... 17
3.1 Main Power Shut-Off Switch ..................................................................................................17
3.2 All Off Button (Station/Wayside Only)....................................................................................17
3.3 Vacuum System (Station/Wayside Only).................................................................................18
3.3.1 Vacuum Intended Use...............................................................................................................................18
3.3.2 Vacuum Safety Information ......................................................................................................................18
3.3.3 Vacuum Button Operation ........................................................................................................................19
3.3.4 Vacuum Hose ............................................................................................................................................19
3.3.5 Tank Capacity ............................................................................................................................................20
3.4 Blower System (Station/Wayside Only) ..................................................................................20
3.4.1 Blower Intended Use.................................................................................................................................20
3.4.2 Blower Safety Information ........................................................................................................................20
3.4.3 Blower Button Operation..........................................................................................................................21
3.4.4 Blower Hose ..............................................................................................................................................21
3.4.5 Blow Gun...................................................................................................................................................22
3.4.6 Compressor Operation..............................................................................................................................22
3.5 Hand Tools ............................................................................................................................23
3.5.1 Cable Reels ................................................................................................................................................23
3.5.2 Brush .........................................................................................................................................................23
3.5.3 Reach Grabber ..........................................................................................................................................24
3.5.4 Plug Wrench..............................................................................................................................................24

CD3 Products Manual
CD3, General Benefit Corporation | www.cd3station.com | [e-mail] | 612.467.9441
Patent Pending | Made in USA | © 2019
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3.6 Lights.....................................................................................................................................24
3.7 Trailer (Wayside 120V and Wayside Solar Only) ......................................................................25
3.7.1 Trailer Intended Use..................................................................................................................................25
3.7.2 Trailer Safety Information .........................................................................................................................26
3.7.3 Trailer Lowering/Crank Down Procedure..................................................................................................28
3.7.4 Solar Panel Tie Down (Trailered Wayside Solar Only)...............................................................................29
3.8 Battery Charging (Trailered Wayside Units Only).....................................................................31
3.8.1 Charging Procedure...................................................................................................................................31
3.8.2 Charger Safety Information.......................................................................................................................32
3.8.3 Extension Cord Requirements...................................................................................................................32
3.8.4 Partial Recharging .....................................................................................................................................32
3.8.5 Charge Time ..............................................................................................................................................32
3.8.6 Battery Break-In ........................................................................................................................................33
3.8.7 Depth of Discharge....................................................................................................................................33
Section 4 –Maintenance and Care ....................................................................................... 33
4.1 Vacuum System (Station/Wayside Only).................................................................................34
4.1.1 Tank Emptying...........................................................................................................................................34
4.1.2 Vacuum Pressure Relief Valve...................................................................................................................35
4.1.3 Inspect Hose..............................................................................................................................................35
4.2 Blower/Compressor (Station/Wayside Only) ..........................................................................36
4.2.1 Blower/Compressor Maintenance Safety .................................................................................................36
4.2.2 Air Pressure Regulator ..............................................................................................................................37
4.2.3 Relief Valve................................................................................................................................................37
4.2.4 Air Filter.....................................................................................................................................................38
4.2.5 Air Leaks ....................................................................................................................................................38
4.2.6 Compressor Oil..........................................................................................................................................38
4.2.7 Compressor Belts (Station Only) ...............................................................................................................39
4.3 Tool Reels .........................................................................................................................40
4.3.1 Reel Lubrication ........................................................................................................................................40
4.3.2 Cable Inspection........................................................................................................................................40
4.3.3 Tension Adjustment ..................................................................................................................................40
4.3.4 Spring Replacement ..................................................................................................................................40
4.3.5 Reel Sensors ..............................................................................................................................................40
4.3.6 Tool Replacement .....................................................................................................................................41
4.4 Batteries (Wayside/Outpost Only)..........................................................................................41
4.4.1 Battery Safety Precautions........................................................................................................................41
4.4.2 Battery Pack Inspection.............................................................................................................................42
4.4.3 Battery Cleaning........................................................................................................................................43
4.4.4 Battery Disposal ........................................................................................................................................43
4.5 Fuses .....................................................................................................................................43
4.6 Trailer (Wayside120V and Wayside Solar Units Only) ..............................................................44
4.6.1 Greasing Wheel Bearings ..........................................................................................................................44
4.6.2 Tire Pressure .............................................................................................................................................45
4.6.3 Lift System Inspection ...............................................................................................................................45

CD3 Products Manual
CD3, General Benefit Corporation | www.cd3station.com | [e-mail] | 612.467.9441
Patent Pending | Made in USA | © 2019
5
4.7 Storage/Winterization ...........................................................................................................45
4.6.1 Cover .........................................................................................................................................................45
4.6.3 Compressor in Storage (Station/Wayside Only) .......................................................................................46
4.6.2 Batteries in Storage (Wayside/Outpost Only)...........................................................................................46
4.7 Care and Cleaning ..................................................................................................................47
4.8 Key Replacement ...................................................................................................................47
4.9 Maintenance Schedule Table..................................................................................................48
Section 5 –Theory of Operation ........................................................................................... 49
5.1 Control System ......................................................................................................................49
5.1.1 Control Module .........................................................................................................................................49
5.1.2 Cellular Gateway .......................................................................................................................................49
5.1.3 Function Buttons.......................................................................................................................................49
5.2 Station...................................................................................................................................49
5.2.1 Compressor ...............................................................................................................................................50
5.2.2 Vacuum .....................................................................................................................................................50
5.2.3 Lights .........................................................................................................................................................50
5.3 Wayside (Solar and 120V) ......................................................................................................50
5.3.1 Battery Pack ..............................................................................................................................................50
5.3.2 Solar Panels/Solar Charging ......................................................................................................................51
5.3.3 120V Charger.............................................................................................................................................51
5.3.4 Compressor ...............................................................................................................................................51
5.3.5 Vacuum .....................................................................................................................................................52
5.3.6 Lights .........................................................................................................................................................52
5.4 Outpost .................................................................................................................................52
5.4.1 Battery Pack ..............................................................................................................................................52
5.4.2 Solar Panels/Solar Charging ......................................................................................................................52
5.4.3 Light...........................................................................................................................................................52
Section 6 –Digital Tools....................................................................................................... 53
6.1 Web Resources ......................................................................................................................53
6.2 Equipment WiFi Resources.....................................................................................................53
Section 7 –Customer Assistance Information ....................................................................... 53
Section 8 –Warranty Statement .......................................................................................... 54

CD3 Products Manual
CD3, General Benefit Corporation | www.cd3station.com | [e-mail] | 612.467.9441
Patent Pending | Made in USA | © 2019
6
Section 1 –General Unit Overview
1.1 Unit Model Descriptions
1.1.1 Station
The Station unit is designed to be mounted in a single location and permanently affixed
to a concrete base. It utilizes a large industrial wet or dry vacuum, a compressed air
blower, and three hand tools. The hand tools include a long-handled brush, plug wrench
and reach grabber all attached to cable reels for tool retention. The unit is illuminated
with 2 lights at the lower edges of the body and two on a light pole centered above the
body.
The Station differs from its siblings in that it is powered by 220VAC power which powers
an industrial grade compressor and vacuum motor to power the equipment. It is not
power limited in use of any of its features.
1.1.2 Wayside 120V
The Wayside 120V unit retains the same outer functions of the Station (vacuum, blower,
and three hand tools). It differs from the Station unit in that it is powered by 120VAC.
This is achieved by the use of a battery pack and charger. This unit uses the stored power
to provide similarly functioning vacuum and blower. The unit uses an on-demand tank-
less compressor for the blower which produces similar output as the station unit. The
difference is that it draws power only when in use and does not have a tank to store
energy in the form of air. The vacuum is still an industrial grade, but has slightly less
power due to the supply power limitations. Those power supply limitations also amount
to a lower amount of consecutive run time than the Station unit. This unit can function
as a stationary unit and be mounted to a concrete pad like the Station where it would
need supply power and just remain plugged in. Due to the battery pack, it is also able to
be mounted a to a trailer frame for mobility between use sites.
1.1.3 Wayside Solar
The Wayside solar unit is designed to be mounted in a single location and permanently
affixed to a concrete base. It retains the same outer functions of the Station and
Wayside 120V (vacuum, blower, and three hand tools). It also retains the same
compressor, vacuum and battery configuration as its closer sibling the Wayside 120V
unit. It differs from the Wayside 120V in that it uses its solar panels to charge the battery
pack as opposed to requiring a 120VAC power source. Componentry is all the same, but

CD3 Products Manual
CD3, General Benefit Corporation | www.cd3station.com | [e-mail] | 612.467.9441
Patent Pending | Made in USA | © 2019
7
it uses a solar charger instead of a 120V supply charger to feed the battery pack. The
limitations of the unit are the power supply that it uses. This amounts to a lower amount
of consecutive run time than the Station or Wayside unit. Recharge time is also variant
depending on the location specifics. The main benefit of the solar function is that this
unit requires no on-site power supply.
1.1.4 Outpost
The Outpost unit differs the most from it sibling models than the other units. It is a much
simplified version that uses only three hand tools and lights. Like the Wayside units, it is
powered by a battery pack. The pack is appropriately sized to accommodate its much
less power demand than the Wayside units. The only powered features in the unit are
the lights and internal logic system. It also uses solar panels to supply power, so no on-
site power supply is required. The outpost is only limited in consecutive uses of the light
function.
1.1.5 Trailer Option (Wayside 120V and Wayside Solar Only)
The ability to mount the unit to a trailer is possible with the Wayside 120V and Wayside
Solar units. The trailer provides a way to move the unit from site to site and also has a
built-in apparatus that allows the trailer base to be lowered to rest on the ground for
ease of access to the unit. The trailered option places the unit on a road-capable, heavy
duty trailer base that uses a hand crank system to lower to the ground. There are
leveling legs for ground that is not perfectly flat. The trailer is equipped with full lighting
for the road. It also has a deck space at the rear of the trailer for transport of other
larger items with the unit.

CD3 Products Manual
CD3, General Benefit Corporation | www.cd3station.com | [e-mail] | 612.467.9441
Patent Pending | Made in USA | © 2019
8
1.2 Unit Layouts and Features
1.2.1 Overview Station/Wayside - Front
1. Blower Function Button (sec. 3.4.3)
2. Light Function Button (sec. 3.6)
3. “All Off” Function Button (sec. 3.2)
4. Upper Lights (sec. 3.2)
5. Vacuum Function Button (sec 3.3.3)
6. Vacuum Hose (sec. 3.3.4)
7. Vacuum Hose Rack
8. Body Light (sec. 3.2)
9. Reach Grabber (Tool 3) (sec. 3.5.3)
10. Plug Wrench (Tool 2) (sec. 3.5.4)
11. Brush (Tool 1) (sec. 3.5.2)
12. Fork Tunnel
13. Air Blow Gun Holster
14. Air Blow Gun Hose Rack
15. Air Blow Gun Hose (sec. 3.4.4)
16. Air Blow Gun (sec. 3.4.5)

CD3 Products Manual
CD3, General Benefit Corporation | www.cd3station.com | [e-mail] | 612.467.9441
Patent Pending | Made in USA | © 2019
9
1.2.2 Overview- Station/Wayside - Rear
1. Service Door
2. Vacuum Tank Clean-Out
3. Data Logger Antenna
4. Compressor Cooling Vents
5. Service Door Lift-Off Hinges
6. Fork Tunnel
7. Vacuum Exhaust Outlet

CD3 Products Manual
CD3, General Benefit Corporation | www.cd3station.com | [e-mail] | 612.467.9441
Patent Pending | Made in USA | © 2019
10
1.2.3 Overview –Outpost
1. Light Button Function (sec. 3.6)
2. Upper Light (sec. 3.6)
3. Solar Panels
4. Data Logger Antenna
5. Reach Grabber (Tool 3)(sec. 3.5.3)
6. Plug Wrench (Tool 2) (sec. 3.5.4)
7. Lower Light (sec. 3.6)
8. Brush (Tool1) (sec. 3.5.2)
9. Service Door
10. Service Door Lift-Off Hinges