Hyden ENVIROSPRAY User manual

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 1
Hyden Engineering Pty Limited
1/48 Racecourse Road
RUTHERFORD NSW 2320
Telephone: [phone]
Facsimile: [phone]
E-mail:[email protected]
ABN: 17 129 010 902
Manual Date: June 2011Manual Number: 06500978A
Diagnostics
ENVIROSPRAY Manual

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 2
Hyden Engineering
Contents
25Road Speed system2.7
24Spot Spray system2.6 24System wont start2.6.1
23System wont start2.5.1 23AUX systems2.5
22Foam System2.4 22System wont start2.4.1
19Right Spray/s not working2.1.4 18Centre Spray not working2.1.3 17Left Spray/s not working2.1.2
21Foot Pedal wont work2.3.1
20System Wont Start2.2.1
16Spray System wont start2.1.1
15Remote Cannon Up Control1.4.7 14Remote Cannon Down Control1.4.6 13Remote Cannon Fog Control1.4.5 12Remote Cannon Jet Control1.4.4 11Remote Cannon Right Control1.4.3 10Remote Cannon Left Control1.4.2 9Remote Cannon Water Control1.4.1 9Remote Cannon1.4 8System Diagnostics1.3.1 8Foam System1.3 7Spray Head not opening1.2.2 6Spray Head leaking or not closing1.2.1
5System Diagnostics1.1.2 4System Diagnostics1.1.2 3System Diagnostics1.1.1
21Foot Pedal2.3
16Spray System2.1
20Cannon System2.2
25System wont start2.7.1
16Electric System Diagnostics2
6Spray Box Control1.2
3Water Pump Module & Sequence Valve1.1 3System Diagnostics1
Page
Number
Topic
Reference
Number

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 3
Hyden Engineering
1.1 Water Pump Module & Sequence valve
1.1.1 System diagnostics
1SystemDiagnostics
No
Yes
Connect the test gauge to test point PR.
Is the gauge reading between 20 and 25-bar?
See Diagnostics 1.1.3See Diagnostics 1.1.2
Adjust sequence valve to 180-bar.
If the coil LED is illuminated and
pressure less than 20-bar replace
sequence valve. If the plug is not
illuminated there is an electric fault.
Did this fix the problem?
Congratulations you
have fixed the problem.
Close the isolation ball valve
and start the system.
Does the sequence valve
pressure read between
180-bar and 190-bar?
Yes
No
Yes No
Sequence valve pressure test point
Isolation Ball valve
Sequence valve
engage solenoid
Sequence valve adjustment
Test Gauge on Test Point PR System pressure gauge
Typical Sequence Valve Mounting and Location

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 4
Hyden Engineering
Connect the test gauge to test point X.
Does the pressure increase from 0-bar to approx 9-bar
as the water rate is increased from Low to High?
Set system at High. Does
the system pressure read
175-bar?
Slowly increase the manual
override on the solenoid valve.
Does the pressure increase from
0-bar to above 15-bar as the
adjustment is screwed in?
Replace the solenoid
valve.
Did this fix the problem?
There is ether an
electrical fault or the
coil is faulty.
Yes No
Yes No
Congratulations you
have fixed the
problem.
Did this fix the
problem?
Slowly adjust the
compensator dump valve
until the system pressure
reaches 175-bar.
Did the compensator
adjust correctly?
The system is
functioning correctly,
the problem is likely
to be with the water
pump.
Replace and retest.
Yes No
Replace the
water module
Yes No
Yes No
Congratulations you
have fixed the
problem.
Replace the
water module
Yes No
Replace the
water module
1.1.2 System diagnostics
Test Point X System pressure gauge
Compensator dump valve
Solenoid valve
Manual override

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 5
Hyden Engineering
Adjust the pressure reducer valve
to 20-bar.
Did the pressure adjust correctly?
Did this fix the
problem? Replace the pressure reducer.
Does the pressure now read
between 20 and 25-bar?
Congratulations you
have fixed the
problem. Replace water
module
See Diagnostic 1.1.2
Yes No
Yes No
Yes No
Did this fix the
problem
Congratulations you
have fixed the
problem.
Yes
No
1.1.3 System diagnostics
Test Point X System pressure gauge
Compensator dump valve
Solenoid valve
Manual override

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 6
Hyden Engineering
1.2 Spray Control Box
1.2.1 Spray head leaking or not closing
Yes
Yes No
Spray head or heads leaking or
not closing
Connect the test gauge to test point TP. Is
the gauge reading above 20-bar when the
machine is off?
Ensure accumulator bleed valve is
shut and retest if it was open.
Connect the test gauge to the test point
associated to the leaking spray head. Is
the gauge reading approx 20-bar?
Ensure positive sealing valve
manual override is IN and retest if
it was out.
Spray head faulty,
replace and retest
Change out spray box and
send for repair
Ensure spray head
solenoid valve
manual override is
IN. Change out
solenoid valve.
No
Congratulations you
have fixed the
problem.
Did this fix the
problem Did this fix the
problem
No No Yes No
Congratulations you
have fixed the
problem.
Congratulations you
have fixed the
problem.
Test point TP Accumulator
bleed valve
Positive sealing valve
Spray head test
points (depending on
number in system) Typical mounting of HYDEN391 Spray Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 7
Hyden Engineering
Spray head or heads not
opening
Yes Is the associated solenoid LED illuminated?
Check switches in drivers cab
are in the correct position and
retest if they were not.
Connect the test gauge to the test point
associated to the faulty spray head. Is
the gauge reading below 4-bar?
No
Yes No
Spray head faulty,
replace and retest Change out
solenoid valve.
Change out spray box and
send for repair
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Did this fix the
problem?
Yes No
1.2.2 Spray heads not opening
The problem is an
electrical fault. See
electrical diagnostics
Congratulations you
have fixed the
problem.
Test point TP Accumulator
bleed valve
Positive sealing valve
Spray head test
points (depending on
number in system) Typical mounting of HYDEN391 Spray Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 8
Hyden Engineering
1.3 Foam system
1.3.1 System Diagnostics
Foam system not working
Yes No
Yes No
There is a fault with the
foam pump module.
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Ensure the foam inlet ball valve is completely open.
Increase the Vari-rate to 40%.
Does the MID foam LED illuminate and the drive
shaft continue to rotate?
Engage the LOW foam
manual override.
Does the foam system start
to work?
While using the remote cannon set the Vari-
rate to low and start the foam system.
Does the Low foam LED illuminate and the
drive shaft start to rotate?
Increase the Vari-rate
further to 80%.
Do both the Low and
Mid LED plug
illuminate ?
There is an electrical fault.
See electrical diagnostics
Engage the MID foam
manual override.
Does the foam system start
to work ?
There is a fault with the
foam pump module.
Yes No
There is an electrical fault.
See electrical diagnostics
No
Setup a REV counter on the drive shaft.
Vari-rate @ low = 160-rpm Adjust Low flow control as required
Vari-rate @ 40% = 340-rpm Adjust Mid flow control as required
No Yes
Inlet pressure
test point
LOW foam
MID foam
MID foam
flow control
LOW foam
flow control
Increase
Decrease
Motor drive
pressure test
point

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 9
Hyden Engineering
Yes
Yes No
Cannon water valve not
opening
Set the cannon to the ON position. Is the
associated coil LED illuminated?
Connect the test gauge to test point B7.
Is the gauge reading approx 20-bar?
Connect the test gauge to
test point A7. Is the gauge
reading below 4-bar?
No
Test point A7
Cannon
On/Off valve
Test point B7
Change out
solenoid valve.
Change out spray box and
send for repair
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Yes
No
The problem is
likely the Cannon
valve.
Check switches in drivers cab
are in the correct position and
retest if they were not.
Did this fix the
problem?
Yes No
The problem is an
electrical fault. See
electrical diagnostics
Congratulations you
have fixed the
problem.
1.4 Remote cannons
1.4.1 Remote cannon water control
HYDEN409-B
Cannon Control Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 10
Hyden Engineering
1.4.2 Remote cannon left control
Yes
Yes No
Cannon not moving turning left
Set the cannon to the left position. Is the left
coil LED illuminated?
Connect the test gauge to test point B1.
Is the gauge reading approx 20-bar?
Connect the test gauge to
test point A1. Is the gauge
reading below 4-bar?
No
Change out
solenoid valve.
Change out spray box and
send for repair
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Yes
No
The problem is
likely the Cannon
actuator.
Check controls in drivers cab
are in the correct position and
retest if they were not.
Did this fix the
problem?
Yes No
The problem is an
electrical fault. See
electrical diagnostics
Congratulations you
have fixed the
problem.
Test point A1
Cannon Left
Right valve
Test point B1 HYDEN409-B
Cannon Control Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 11
Hyden Engineering
1.4.3 Remote cannon right control
Yes
Yes No
Cannon not moving turning right
Set the cannon to the right position. Is the
right coil LED illuminated?
Connect the test gauge to test point B1.
Is the gauge reading approx 20-bar?
Connect the test gauge to
test point A1. Is the gauge
reading below 4-bar?
No
Change out
solenoid valve.
Change out spray box and
send for repair
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Yes
No
The problem is
likely the Cannon
actuator.
Check controls in drivers cab
are in the correct position and
retest if they were not.
Did this fix the
problem?
Yes No
The problem is an
electrical fault. See
electrical diagnostics
Congratulations you
have fixed the
problem.
Test point A1
Cannon Left
Right valve
Test point B1 HYDEN409-B
Cannon Control Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 12
Hyden Engineering
1.4.4 Remote cannon jet control
Yes
Yes No
Cannon adjusting from Fog to Jet
correctly
Set the cannon to the jet position. Is the jet
coil LED illuminated?
Connect the test gauge to test point A3.
Is the gauge reading approx 20-bar?
Connect the test gauge to
test point B3. Is the gauge
reading below 4-bar?
No
Change out
solenoid valve.
Change out spray box and
send for repair
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Yes
No
The problem is
likely the Cannon
actuator.
Check controls in drivers cab
are in the correct position and
retest if they were not.
Did this fix the
problem?
Yes No
The problem is an
electrical fault. See
electrical diagnostics
Congratulations you
have fixed the
problem.
Test point A3
Cannon Jet
Fog valve
Test point B3 HYDEN409-B
Cannon Control Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 13
Hyden Engineering
1.4.5 Remote cannon fog control
Yes
Yes No
Cannon adjusting from Jet to Fog
correctly
Set the cannon to the fog position. Is the fog
coil LED illuminated?
Connect the test gauge to test point B3.
Is the gauge reading approx 20-bar?
Connect the test gauge to
test point A3. Is the gauge
reading below 4-bar?
No
Change out
solenoid valve.
Change out spray box and
send for repair
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Yes
No
The problem is
likely the Cannon
actuator.
Check controls in drivers cab
are in the correct position and
retest if they were not.
Did this fix the
problem?
Yes No
The problem is an
electrical fault. See
electrical diagnostics
Congratulations you
have fixed the
problem.
Test point A3
Cannon Jet
Fog valve
Test point B3 HYDEN409-B
Cannon Control Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 14
Hyden Engineering
1.4.6 Remote cannon down control
Yes
Yes No
Cannon not moving down
Set the cannon to the down position. Is the
down coil LED illuminated?
Connect the test gauge to test point B2.
Is the gauge reading approx 20-bar?
Connect the test gauge to
test point A2. Is the gauge
reading below 4-bar?
No
Change out
solenoid valve.
Change out spray box and
send for repair
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Yes
No
The problem is
likely the Cannon
actuator.
Check controls in drivers cab
are in the correct position and
retest if they were not.
Did this fix the
problem?
Yes No
The problem is an
electrical fault. See
electrical diagnostics
Congratulations you
have fixed the
problem.
Test point A2
Cannon Up
Down valve
Test point B2 HYDEN409-B
Cannon Control Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 15
Hyden Engineering
1.4.7 Remote cannon up control
Yes
Yes No
Cannon not moving up
Set the cannon to the up position. Is the up
coil LED illuminated?
Connect the test gauge to test point B2.
Is the gauge reading approx 20-bar
Connect the test gauge to
test point A2. Is the gauge
reading below 4-bar?
No
Change out
solenoid valve.
Change out spray box and
send for repair
Did this fix the
problem?
Yes No
Congratulations you
have fixed the
problem.
Yes
No
The problem is
likely the Cannon
actuator.
Check controls in drivers cab
are in the correct position and
retest if they were not.
Did this fix the
problem?
Yes No
The problem is an
electrical fault. See
electrical diagnostics
Congratulations you
have fixed the
problem.
Test point A2
Cannon Up
Down valve
Test point B2 HYDEN409-B
Cannon Control Box

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 16
Hyden Engineering
2.1 Spray system
2.1.1 System Won’t Start
2 Electric System Diagnostics
Display Panel
P/No: VSS10C
System Won’t Turn On
Yes
Do the following points into the Control
Module have the correct supply voltage?
•CN01/Pin 5 = +24V
•CN01/Pin 6 = Ground
•CN02/Pin 1 = +24V
No
Turn the Spray System toggle switch on.
Is there still a problem?
Replace the Control Module
P/No: VSS10A
Is the Spray System toggle switch
turned on?
Yes
No
Do the following points into the Operator
Console have the correct supply voltage?
•CN04/Pin 1 = +24V
•CN04/Pin 2 = Ground
Do the following points into the Display
Panel have the correct supply voltage?
•Pin 1 = +24V
•Pin 2 = Ground
Yes
Replace the Control Module
P/No: VSS10C
No
Replace the Display Panel
P/No: VSS10C
Yes
Use Electrical Schematic to
diagnose power supply
problems.
No
Yes
Congratulations you
have fixed the
problem.
No
Control Module
P/No: VSS10A
CN02
Red Harness
CN01
Green Harness
CN04
Blue Harness
Spray System
Toggle Switch

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 17
Hyden Engineering
2.1.2 Left Spray/s Not working
Left Spray/s Won’t Turn On
Is the respective Spray toggle switch
turned on?
Turn the respective toggle switch on.
Is there still a problem?
Is there +24v at Input CN02/Pin 2?
Yes No
Is there +24v at Output CN06/Pin 2?
Yes
Is the Pedal Indicator on?
Yes
Turn the Foot Pedal on.
Is there still a problem?
No
Use the Electrical Schematic to diagnose
wiring circuit problem.
No
Is there +24v at the respective Spray
Solenoid Valve?
Yes
Is the Left Spray Valve Circuit Breaker
on the front of the Control Module
tripped?
No
Reset the Circuit
Breaker & re-test.
Replace the respective Spray Solenoid
Valve
Yes
Replace the Main
Control Module
P/No: VSS10A
YesNo
Use the Electrical
Schematic to diagnose
wiring circuit problem.
No
Congratulations you
have fixed the
problem.
No
Yes
Congratulations you
have fixed the
problem.
No
Display Panel
P/No: VSS10C
CN02
Red Harness
CN06
Black Harness
Left Spray
Circuit Breaker
Control Module
P/No: VSS10A
Typical left
spray switch/s
Foot Pedal

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 18
Hyden Engineering
2.1.3 Centre Spray Not working
Display Panel
P/No: VSS10C
CN02
Red Harness
CN06
Black Harness
Centre Spray
Circuit Breaker
Control Module
P/No: VSS10A
Centre spray
switch
Foot Pedal
Centre Spray Won’t Turn On
Is the Centre Spray toggle switch
turned on?
Turn the Centre Spray toggle switch on.
Is there still a problem?
Is there +24v at Input CN02/Pin 3?
Yes No
Is there +24v at Output CN06/Pin 3?
Yes
Is the Pedal Indicator on?
Yes
Turn the Foot Pedal on.
Is there still a problem?
No
Use the Electrical Schematic to diagnose
wiring circuit problem.
No
Is there +24v at the Centre Spray
Solenoid Valve?
Yes
Is the Centre Spray Valve Circuit
Breaker on the front of the Control
Module tripped?
No
Reset the Circuit
Breaker & re-test.
Replace the Centre Spray Solenoid
Valve
Yes
Replace the Main
Control Module
P/No: VSS10A
YesNo
Use the Electrical
Schematic to diagnose
wiring circuit problem.
No
Congratulations you
have fixed the
problem.
No
Yes
Congratulations you
have fixed the
problem.
No

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 19
Hyden Engineering
2.1.4 Right Spray/s Not working
Display Panel
P/No: VSS10C
CN02
Red Harness
Right Spray
Circuit Breaker
Control Module
P/No: VSS10A
Typical right
spray switch/s
Foot Pedal
Right Spray/s Won’t Turn
On
Is the respective Spray toggle switch
turned on?
Turn the respective toggle switch on.
Is there still a problem?
Is there +24v at Input CN02/Pin 4?
Yes No
Is there +24v at Output CN06/Pin 4?
Yes
Is the Pedal Indicator on?
Yes
Turn the Foot Pedal on.
Is there still a problem?
No
Use the Electrical Schematic to diagnose
wiring circuit problem.
No
Is there +24v at the respective Spray
Solenoid Valve?
Yes
Is the Right Spray Valve Circuit Breaker
on the front of the Control Module
tripped?
No
Reset the Circuit
Breaker & re-test.
Replace the respective Spray Solenoid
Valve
Yes
Replace the Main
Control Module
P/No: VSS10A
YesNo
Use the Electrical
Schematic to diagnose
wiring circuit problem.
No
Congratulations you
have fixed the
problem.
No
Yes
Congratulations you
have fixed the
problem.
No
CN06
Black Harness

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 20
Hyden Engineering
Display Panel
P/No: VSS10C
Cannon Circuit
Breaker
Control Module
P/No: VSS10A
Typical
Cannon ON
switch/s
2.2 Cannon System
2.2.1 System Won’t start
Cannon/s Won’t Turn On
Is the respective Cannon toggle switch
turned on?
Turn the respective toggle switch on.
Is there still a problem?
Is there adequate supply at the following?
•CN02/Pin 6 = +24V
•CN01/Pin 5 = +24V
•CN01/Pin 6 = Ground
Yes No
Is there +24v at Output CN06/Pin 6?
Yes
Is the Pedal Indicator on?
Yes
Turn the Foot Pedal on.
Is there still a problem?
No
Use the Electrical Schematic to
diagnose wiring circuit problem.
No
Is there +24v at the respective Cannon
Solenoid Valve?
Yes
Is the Cannon Valve Circuit Breaker on
the front of the Control Module tripped?
No
Reset the Circuit
Breaker & re-test.
Replace the respective Solenoid Valve
Yes
Replace the Main
Control Module
P/No: VSS10A
YesNo
Use the Electrical
Schematic to diagnose
wiring circuit problem.
No
Congratulations you
have fixed the
problem.
No
Yes
Congratulations you
have fixed the
problem.
No
Foot Pedal
CN02
Red Harness
CN06
Black Harness
CN01
Green Harness