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
ENVIROSPRAY Manual
Manual Date: June 2011Manual Number: 06500976A
System Background and Operation

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 2
Hyden Engineering
Contents
23Speed Sensor Monitor2.5.2
13Road Speed Control2.2.3 10Spot Spraying2.2.2 8Basic Spraying2.2.1
5Spray Toggle Switches2.1.1 5Auxiliary Outlets Switch2.1.2 5Using the Pause Function2.1.3 5Power Indicator2.1.4 6Vari-Spray Buttons2.1.5 6Road Speed2.1.6 6Spot Spray2.1.7 7Display Window2.1.8 7Pedal Indicator2.1.9 7Centre Spray Indicator2.1.10 7Left Spray Indicator2.1.11 7Right Spray Indicator2.1.12 7Cannon Switch/s2.1.13 7Cannon Controls2.1.14 7Foam Injection Switch (optional)2.1.15
15Combination Spraying2.2.4
7Jet/Fog Switch (optional)2.1.16
19Basic Cannon Operation2.3.1 21Using the Auxiliary2.4 21Auxiliary Systems2.4.1 22System Controls2.5 22Tank Level Monitoring System2.5.1
24Motor Filter Sensor2.5.3 24Motor Failing Sensor2.5.4
19Using the Remote Cannon2.3
5System Controls2.1
8Using the Spray System2.2
5System Operation23Background1.1 3Enviro-Spray1
Page
Number
Topic
Reference
Number

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 3
Hyden Engineering
1.1 Background
Enviro-spray™was specifically developed to be a plug and play system that optimises the use of limited water
supplies while still maintaining the dust control barrier required by regulations. The user interface has been
simplified by replacing the old dial type control with a user-friendly up-down push button control, foot pedal
stop-start switch and LCD display. The Enviro-spray™push button control sets the water flow rate, road speed
and spot spray distances while constantly measuring the water level, filter condition and motor condition. The
system can be preset to have default water flow rates, road speed settings and spot spray distances so that the
operator may simply select road speed, spot spray or both and drive while the Enviro-spray™system takes
control. It will stop and start the water flow at intersections and automatically adjusts the water flow rate as the
machine speeds up and slows down while also stopping and starting to provide the set wet and dry distances.
Night time dust control has always been a daunting task for operators as they could not see the spray while
driving and constantly had to adjust the flow control dial as they sped up and slowed down. The Enviro-spray™
road speed control has changed the face of night time dust control by giving the operator the confidence to
preset the system to suit the conditions prior to driving and can have confidence that the Enviro-spray™system
will do the job.
Enviro-spray™also converted the first response capability of a standard water truck to a new level giving water
throw in excess of 70-meters with an automatic foam injection system adjusting the foam to suit the desired
water rate and this increases the efficiency of the limited foam supply. The Enviro-spray™foam injection
system also allows the use of multiple outlets so that foam may be simultaneously supplied to all water cannons,
fire hose reel and Excavator backup systems giving the system the ability to become the hub of the fire fighting
response.
1 Enviro-Spray™

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Hyden Engineering
Maintenance was also kept top of mind in the development of the Enviro-spray™system and this has been
optimised by the use of separate modules for each key component, oversize filtration and with conditional
indicators giving feedback to the operator. Each key control valve used in the Enviro-spray™system has its
own set of pressure test points and pressure gauge together with manual overrides so that diagnostics can be
performed using these test points while following the simple diagnostic tree on the door of the control valve
box. The system can be manually overridden if required to allow maintenance to be scheduled at a convenient
time.
Connection of the Enviro-spray™hydraulics involves fitting the Enviro-spray™soft start sequence valve in the
line from the hoist pump pressure filter and connecting the return line from the Enviro-spray™water pump
module to the original hoist valve. There is no loss of brake cooling and the soft start sequence valve prevents
the usual shock load when starting the water system since there is adequate pressure to cause the water pump to
slowly rotate while unloaded. The Enviro-spray™system also drops the average running pressure of the hoist
pump to below 70-bar (1000-psi) in place of the 175-bar (2500-psi) seen with flow control systems and this
significantly reduces the wear on the hoist pump and removes the overheating problem commonly associated
with water truck hydraulics. The filtration system fitted to the Enviro-spray™water pump module works as a
full flow kidney system filtering the hydraulic oil to 20-micron.
The basic system consists of a hydraulic pressure sequence valve and water pump module with an electric
control system to provide all the basic features such as water rate proportional to road speed, fixed flow rate
independent of engine speed and a positive start and stop spot spray with adjustable wet/dry distances. Options
such as Enviro-spray™foam injection, spray head controls, water cannon controls and water level monitoring
can all be added to realise the full potential of the Enviro-spray™system and are simply fitted and plugged into
the control system.
The backbone of the system is the large variable motor that controls the speed of the water pump and replaces
the complex and troublesome flow control valves that overheat the system and limit the power available.
The control system utilises closed loop technology to set the water rate and thus has made it possible to enhance
operator control with features such as, water rate proportional to road speed, fixed rate independent on engine
speed and positive start and stop spot spray with adjustable wet/dry distances.

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 5
Hyden Engineering
2.1 System controls
2 System operation
2.1.1 Spray Toggle Switches
(typical 5 spray system illustrated, layout
may vary)
Spray System Switch
This is the main power switch used to
turn the Enviro-spray System on.
Spray Nozzle Switches
These switches are used to turn on the
corresponding spray heads. A typical
system may have from 3 up to 6 spray
heads.
2.1.2 Auxiliary Outlets Switch
This switch is used to turn the spray
system on without turning spray heads or
remote cannon on. This is primarily used
in conjunction with a manual cannon or
hose reel.
2.1.3 Foot switch
This is used as a master control switch by
turning all sprays and pump off in one
action. It will also turn cannon or
auxiliary outlets off.
2.1.4 Power Indicator
Green indicator will be on while the
spray system is switched on.

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 6
Hyden Engineering
2.1.5 Vari-Spray Buttons
The increase button steps up the variable spray
water volume by one step with each button push.
The maximum setting will be as was set during
the electric default system setup procedure.
LOW, 20%,40%, 60%, 80%, HIGH
The decrease button steps down the variable
spray water volume by one step with each button
push.
HIGH, 80%, 60%, 40%, 20%, Low.
NOTE: Maximum is only set for sprays not for
the cannon or auxiliary water volume.
2.1.6 Road Speed
The yellow road speed button switches between
full Vari-rate water volume control and road
speed variable controlled water
volume.
The yellow road speed indicator will be on when
the road speed function is turned on.
2.1.7 Spot Spray
The red spot spray button turns the distance based
spot spraying feature on or off.
The red spot spray indicator will be on when the
spot spray function is turned on.
Increase spot spray wet distance by one step with
each button push. 5M/5M, 7M/7M, 10M/10M,
15M/15M, 25M/25M, 50M/50M
Decrease spot spray wet distance by one step with
each button push. 50M/50M, 25M/25M,
15M/15M, 10M/10M, 7M/7M, 5M/5M

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Hyden Engineering
2.1.8 Display window
Messages will be displayed in this window to
advise the status of spray operations.
2.1.9 Pedal Indicator
The Pedal indicator will show the status of the
foot pedal (On or Off). The foot pedal will always
default to on when the spray system is turned on.
2.1.10 Centre spray indicator
The Centre spray indicator will show the status of
the centre spray head (On or Off).
2.1.11 Left spray indicator
The Left spray indicator will show the status of
the left spray head/s. (On or Off).
2.1.12 Right spray indicator
The Right spray indicator will show the status of
the right spray head/s (On or Off).
2.1.13 Cannon Switch/s
The Cannon Switches will turn the spray system
on and turn the chosen cannon on in one action.
2.1.14 Cannon Controls
The Joystick is used to position the selected
cannon in the direction of the required water
stream.
The cannon selector switch is used to operate the
selected cannon functions, Up/Down, Left/Right,
Jet/Fog and may be a rotary switch in some cases.
2.1.15 Foam Injection Switch
The Foam switch starts the foam injection system
(if fitted) with the volume automatically adjusted
to suit the water volume set by the Vari-spray
control rate. The foam will not inject if the
cannon or auxiliary switches are not on.
2.1.16 Jet / Fog Switch
The Jet / Fog switch (if fitted) changes the cannon
nozzle to a fog or to a jet stream.

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 8
Hyden Engineering
Step1) Turn the Spray System On
Turn the spray system on by switching
the ‘SPRAY SYSTEM’ toggle switch to
the ‘ON’ position.
The system will go through a short
startup process and the display will show
“System Standby”.
Step2) Select which sprays you require
Turn the required spray switches on and
the display indicators will show which
spray heads have been activated.
Note: in a system with more than 3 spray
heads adjacent spray heads may share an
indicator. e.g. For the illustrated 5 spray
system, switching on either the left or
left-inner spray will illuminate the ‘left’
display indicator.
The screen will also display the default
Vari-Rate (water volume) that the sprays
have started at.
Note: The default Vari-rate was set
during the electric default system setup
procedure to suit the average operating
conditions.
2.2 Using the spray system
2.2.1 Basic spraying

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 9
Hyden Engineering
Step3) Using the Pause Function.
The Pause Switch is used to stop the
pump and sprays in one action. The
display will show “Sprays Stopped”. Use
the Pause Switch again and the system
will revert back to the setting prior to
operating the Pause Switch.
Note: Systems are either fitted with a
Foot Pedal or Toggle Switch to operate
the Pause Function as requested on
installation.
Step4) Adjusting the Vari-rate
Use the Vari-spray increase and decrease
buttons to change the water volume as
required.
The display will show the Vari-rate that
has been selected.
Low, 20%, 40%, 60%, 80% or High
Note: Maximum Vari-rate is set during
commissioning via the setup menu and
may be change by your technical
department.

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 10
Hyden Engineering
Step1) Turn the Spray System On
Turn the spray system on by switching
the ‘SPRAY SYSTEM’ toggle switch to
the ‘ON’ position.
The system will go through a short
startup process and the display will show
“System Standby”.
Step2) Select which sprays you require
Turn the required spray switches on and
the display indicators will show which
spray heads have been activated.
Note: in a system with more than 3 spray
heads adjacent spray heads may share an
indicator. e.g. For the illustrated 5 spray
system, switching on either the left or
left-inner spray will illuminate the ‘left’
display indicator.
The screen will also display the default
Vari-rate (water volume) that the sprays
have started at.
Note: The default Vari-rate was set
during the electric default system setup
procedure to suit the average operating
conditions.
2.2.2 Spot spraying

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 11
Hyden Engineering
Step3) Using the spot spray.
Spot Spraying is based on distance rather
than time and as such should be fully
understood before operating. The Spot
cycle is based on equal distances such
that ‘wet’ distance and ‘dry’ distance are
as per the selection. The selection of this
distance is explained in Step 4
The time that the sprays are on is
dependant both road speed and wet/dry
distance selected.
For example, if the wet/dry distance
selected is 50M/50M and the truck is
traveling at 30kph then the time that the
sprays will operate is: Time on (wet) = 6
seconds , Time off (dry) = 6 seconds
But if the same wet/dry distance is
selected and the truck is traveling at
10kph then the time that the sprays will
operate is: Time on (wet) = 18 seconds ,
Time off (dry) = 18 seconds
The advantage of this system is that the
wet spot distance will be maintained
regardless of truck speed. Whether higher
speeds on haul roads or lower speeds on
ramps the distance selected will remain
constant.
Note: Short Spot lengths are ineffective
if the road speed is beyond the systems
ability to open and close the spray
nozzles. For example if the road speed
is 20kph then the minimum effective
Spot length that should be selected is
7M/7M. This may vary slightly
between systems.
Vari‐Rate=60%
Spot=50M/50M

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 12
Hyden Engineering
Step4) Adjusting the Spot Spray.
There are 6 different Spot Spray wet/dry
distances available that are selected by
pushing the appropriate button to either
increase or decrease the current setting.
The system has been setup for your site
with a default wet/dry distance. This can
be changed easily by using the buttons
provided.
The selectable Spot Spray wet distances
are: 5M/5M , 7M/7M, 10M/10M ,
15M/15M, 25M/25M, 50M/50M
The Display will show the new Spot
distance as it is changed
Vari‐Rate=60%
Spot=50M/50M

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 13
Hyden Engineering
Step1) Turn the Spray System On
Turn the spray system on by switching
the ‘SPRAY SYSTEM’ toggle switch to
the ‘ON’ position.
The system will go through a short
startup process and the display will show
“System Standby”.
Step2) Adjust the Vari-rate.
Set the maximum Vari-spray rate
required by using the increase decrease
buttons until the desired maximum water
rate has been selected.
This maximum Vari-rate becomes the
maximum water rate when the machine
road speed reaches 30kph or above.
2.2.3 Road speed control

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 14
Hyden Engineering
Step3) Start road speed control
Road Speed Spraying is used to
automatically adjust the water volume
from the sprays based on the current road
speed.
The road speed controlled water volume
ramp will start the sprays and pump
automatically when the machine road
speed reaches 2kph and will increase the
Vari-rate proportionally as the machine
road speed increases up to 30kph and at
this point the system will be at the
maximum Vari-rate as selected in Step2.
To turn this feature on simply push the
yellow pushbutton and the yellow LED
indicator will turn on.
The display will show the preset
maximum Vari-rate and “Road Speed
On”
The advantage of Road Speed controlled
sprays is the ability to prevent over
watering at lower speeds while
maintaining sufficient water at higher
speeds.
The added feature of automatic spray
stop when the truck stops prevents
flooding at intersections.
Step4) Select which sprays you require
Turn the required spray switches on and
the display indicators will show which
spray heads have been activated.
Note: in a system with more than 3 spray
heads adjacent spray heads may share an
indicator. e.g. For the illustrated 5 spray
system, switching on either the left or
left-inner spray will illuminate the ‘left’
display indicator.

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 15
Hyden Engineering
Step1) Turn the Spray System On
Turn the spray system on by switching
the ‘SPRAY SYSTEM’ toggle switch to
the ‘ON’ position.
The system will go through a short
startup process and the display will show
“System Standby”.
Step2) Adjust the Vari-rate.
Set the maximum Vari-spray rate
required by using the increase decrease
buttons until the desired maximum water
rate has been selected.
This maximum Vari-rate becomes the
maximum water rate when the machine
road speed reaches 30kph or above.
2.2.4 Combination spraying

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Hyden Engineering
Step3) Start road speed control
Road Speed Spraying is used to
automatically adjust the water volume
from the sprays based on the current road
speed.
The road speed controlled water volume
ramp will start the sprays and pump
automatically when the machine road
speed reaches 2kph and will increase the
Vari-rate proportionally as the machine
road speed increases up to 30kph and at
this point the system will be at the
maximum Vari-rate as selected in Step2.
To turn this feature on simply push the
yellow pushbutton and the yellow LED
indicator will turn on.
The display will show the preset
maximum Vari-rate and “Road Speed
On”
The advantage of Road Speed controlled
sprays is the ability to prevent over
watering at lower speeds while
maintaining sufficient water at higher
speeds.
The added feature of automatic spray
stop when the truck stops prevents
flooding at intersections.
Step4) Select which sprays you require
Turn the required spray switches on and
the display indicators will show which
spray heads have been activated.
Note: in a system with more than 3 spray
heads adjacent spray heads may share an
indicator. e.g. For the illustrated 5 spray
system, switching on either the left or
left-inner spray will illuminate the ‘left’
display indicator.

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 17
Hyden Engineering
Step5) Starting the spot spray.
Spot Spraying is based on distance rather
than time and as such should be fully
understood before operating. The Spot
cycle is based on equal distances such
that ‘wet’ distance and ‘dry’ distance are
as per the selection. The selection of this
distance is explained in Step 4
The time that the sprays are on is
dependant both road speed and wet/dry
distance selected.
For example, if the wet/dry distance
selected is 50M/50M and the truck is
traveling at 30kph then the time that the
sprays will operate is: Time on (wet) = 6
seconds , Time off (dry) = 6 seconds
But if the same wet/dry distance is
selected and the truck is traveling at
10kph then the time that the sprays will
operate is: Time on (wet) = 18 seconds ,
Time off (dry) = 18 seconds
The advantage of this system is that the
wet spot distance will be maintained
regardless of truck speed. Whether higher
speeds on haul roads or lower speeds on
ramps the distance selected will remain
constant.
Note: Short Spot lengths are ineffective
if the road speed is beyond the systems
ability to open and close the spray
nozzles. For example if the road speed
is 20kph then the minimum effective
Spot length that should be selected is
7M/7M. This may vary slightly
between systems.
Vari‐Rate=60%
Spot=50M/50M

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 18
Hyden Engineering
Step6) Adjusting the spot spray.
There are 6 different Spot Spray wet/dry
distances available that are selected by
pushing the appropriate button to either
increase or decrease the current setting.
The system has been setup for your site
with a default wet/dry distance. This can
be changed easily by using the buttons
provided.
The selectable Spot Spray wet distances
are: 5M/5M , 7M/7M, 10M/10M ,
15M/15M, 25M/25M, 50M/50M
The Display will show the new Spot
distance as it is changed
Vari‐Rate=60%
Spot=50M/50M

Date Printed: 07/11/2011 “Commercial-in-Confidence” Page Number: 19
Hyden Engineering
(typical 2 cannon system illustrated,
layout may vary)
Step1) Moving the cannons
The direction that the selected cannon is
pointing can be adjusted using the
joystick control and cannon selector
switch. For Hydraulic cannons the
machine must be running.
Warning: It is important to adjust the
direction prior to starting the system
as the system is capable of causing
serious injuries or damage to anything
in the path of the stream. A minimum
safe working distance will be specified
by your site rules.
Step2) Starting the remote cannons
To start a cannon you simply switch the
respective cannon switch to the on
position and the system will
automatically start up (after a short
startup process) with the Vari-rate set at
the default rate.
The display screen will show “Cannon
On” showing the status of the system.
Step3) Adjusting the Vari-rate
After the cannon has started you can now
adjust the Vari-rate to the desired level or
just leave it on the default setting.
The Vari-rate will be displayed on the
Display screen
Adjusting the Vari-rate is done using the
Vari-rate increase and decrease buttons
until you reach the desired level.
2.3 Using the remote cannon
2.3.1 Basic cannon operation

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Hyden Engineering
Step4) Cannon nozzle adjustment
The Jet and Fog switch can be used to
change the pattern of the cannon water
spray from Jet to Fog or Fog to Jet.
Step5) Using the Pause Switch with
cannon
The Pause Function can be used at any
time to pause the Cannon water flow.
Simply push once to stop and once again
to restart.
The display screen will always show the
Cannon status when it is turned on.
Step6) Using the Foam injection system
The foam injection system (if installed) is
an added tool for firefighting purposes.
The foam will only operate when either
the Cannon or the Auxiliary is on.
When the Cannon is on and the Foam
switch is turned on, foam will be directly
injected into the main water flow. The
percentage of foam injection is
automatically adjusted by the control
system to match the current Vari-rate.
Low & 20% = Low Foam
20% & 60% = Medium Foam
40% & High = High Foam
The current Foam injection will be
momentarily displayed each time the
vari-rate is changed and then will revert
back to Cannon On.