HYDRO GUARD LongNeck Standard HG-31 Mounting instructions

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HG-31 LongNeck™Standard
User Operation Manual
Automatic Flushing Devices

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© 2014 Mueller Co.
Hydro-Guard technology is subject to patent.
United States Patent and Trademark Office – All Rights Reserved.
The content of this manual is the sole and exclusive property of Mueller Co.
Unauthorized distribution or reproduction strictly prohibited.
Congratulations on your purchase of the Hydro-Guard® Automatic Flushing System,
the industry’s only patented, programmable flushing apparatus. This HG-31 Automatic
Flushing Unit (U.S. Patent numbers 6,035,704 and 6,880,566) is suitable for use year-
around in moderate to severe cold climates and has been designed, engineered, and
manufactured to provide outstanding dependability and performance.
Please read and retain this manual for future reference.

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Hydro-Guard LongNeck™Unit
(HG-31)
TABLE OF CONTENTS
Page #
Limited Warranty ...................................................4
Safety Procedures & Cautionary Statement. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Procedures & Site Evaluation
Installation of the Unit ..............................................6
Installation Rendering...............................................7
Programming...................................................8 - 11
Options............................................................12
Technical Section
Battery Replacement...............................................14
Disassembly .......................................................15
Reassembly........................................................16
Reloading Dechlorination Chambers ...............................17
Troubleshooting Guide.............................................18
Parts Section
Rendering .........................................................20
Parts List...........................................................21
Notes..........................................................22 - 23

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Hydro-Guard® Limited Warranty
This Hydro-Guard® Automatic Flushing Device is warranted for one year from the
date of delivery. Mueller Co. will repair or replace any defective part or component as
long as the Unit is installed and operated in accordance with the procedures described
within this manual. Damage or failure caused by the improper installation, assembly,
disassembly, maintenance or operation of the Hydro-Guard® Automatic Flushing
Device is not covered by the terms of this warranty. Warranty service is available by
telephoning Mueller Co. at [phone] during regular business hours, or through
contacting the Hydro-Guard Web Site at www.Hydro-Guard.com.
Hydro-Guard® Safety Procedures and Cautionary Statement
CAUTION: Failure to read and follow the instructions contained within this manual
could result in serious personal injury, and/or damage to the Hydro-Guard Automatic
Flushing Device.
• Eachpersoninvolvedintheassembly,installationand/ormaintenanceofthe
Hydro-Guard® Automatic Flushing Device must read this manual carefully
and follow all instructions prior to performing any installation or maintenance
procedures involving the Unit.
• Verifythedrainagepathpriortoinstallationtoensurethatpedestrianandvehicular
hazards will not be created by the installation and use of the Hydro-Guard®
Automatic Flushing Device (In areas in which freezing may occur, special attention
should be given to this procedure).
• Neverassemble,disassemble,orperformHydro-Guard®maintenanceunlessthe
influent supply valve has been closed, verified and secured, and internal piping
pressure has been relieved.
• Alwaysuseallnecessarysafetyequipmentandfollowallrecommended
procedures when installing, operating and maintaining the Hydro-Guard®
Automatic Flushing Device.
• Performannualsafetyinspectionsandreplacewornordefectiveparts.
• OperatetheHydro-Guard®AutomaticFlushingDeviceonlywhenfullyinstalled
and correctly assembled.

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Installation Procedures
& Site Evaluation

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Hydro-Guard® Installation Procedures & Site Evaluation
EachHydro-Guard®installationisuniqueandwillrequireaminimumofadvance
planning. Prior to the installation of the device, the drainage patterns for the intended
installation location should be reviewed. The drainage pattern must permit discharged
water to flow away from the Hydro-Guard® or to be absorbed by the surrounding soil.
The Unit’s ground-level weather seal is designed to prevent infiltration by rainwater
and normal discharges when placed in areas with acceptable drainage. Some utilities
have opted to increase the excavation-site size creating a small drain field, or to
install their Units on concrete splash pads in order to direct runoff. In cold weather
applications multiple nightly flushes are effective in managing discharge volumes and
preventing the accumulation of ice.
Installation of the Hydro-Guard® HG-31 LongNeck™ Unit
Step1
Remove the Hydro-Guard® Unit from its packaging and inspect for possible damage
during shipping.
Step 2
Excavate a suitably sized ditch ensuring it is connected on one side to the utility’s
service line trench. Remove any debris that might create uneven pressure on the Unit.
Compact the bottom of the hole in order to minimize settling after installation. Place
#57 stone then non-compacted clean bedding material within the bottom of the hole.
Turn off service line feed.
Step 3
Slowly lower the Hydro-Guard® Unit into place, pressing it firmly into the non-
compacted bedding material until it is fully seated. Ensure that the Unit is level before
beginning the backfilling operation (The bottom of the ground plate should be
approximately 1” above the final grade).
Step 4
Connect the utility’s water system to the Hydro-Guard® Unit by means of the 2”
threaded connection.
Step 5
Backlltheholearoundtheushingdevicewithcleanlland/or#57stone.Backlling
should be accomplished in 6”compacted lifts. Check that the Unit is level.
Step 6
After installation is complete, sod the area around the Hydro-Guard® Unit or take
other steps in order to prevent erosion. Inspect the area immediately around the Unit
in order to ensure that the existing ground cover is not subject to severe erosion. You
may opt to pour a concrete pad or create a custom installation to best suit your needs.
Step 7
Disinfect the Hydro-Guard® Automatic Flushing Device in accordance with the utility’s
policy. Do not exceed the dosage and contact times recommended by the American
Water Works Association.
Step 8
The Hydro-Guard® Automatic Flushing Device may now be programmed and placed
into service.

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Medium Density Polyethylene
enclosure is UV protected and
offers impact resistance; the upper
secon of the enclosure is
removable and lockable
Superior grade aluminum
diffuser screen diffuses the
discharging water and guards
against nesng rodents, frogs
and snakes
Round cut, 1/2 inch
thick, marine grade
splash plate guards
against erosion and
provides added
stability for the HG-31
The 15-inch diameter below-
grade protecve base is
offered in standard bury
depths ranging from 36” to
108” (custom depths
available). The below grade
base protects the device’s
components from freezing
temperatures and adds
stability for the HG-31.
Stainless security screws
and unique lock protect
the HG-31 from
unauthorized access
Nylon reinforced composite
control valve with an adjustable
control, single piece EPDM
diaphragm and straight-through
pass for debris build-up reducon
(brass upgrade available)
OEM-installed sampling port
and dechlorinaon systems
are standard equipment on
the HG-31
Patented Camlock release
system allows for easy
disassembly and reassembly…
maintenance in minutes
Installaon Drawing

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Programming Your Hydro-Guard® Unit for Operation
Features
The TBOS-II handheld uses on screen prompts for intuitive programming. It will control
current programming interface (T-2– dark gray case), as well as the previous model of
programming interface (T-1 modules programmed by the TBOS-US handheld).
• 1to8possibleushingeventsdaily,oronselecteddaysweekly,365-daycalendar
• Flushduration1minuteto12hours(1minuteincrements)
• Preprogramandstoreupto3dierentschedules
• Rechargeablebattery(lowbatteryindicatorshowsbothhandheldandcontroller
batteryconditions)withrechargingadaptor(9Vlithiumbatterycanbeusedinthe
built-in programming interface)
NOTE: In that the handheld was designed by its manufacturer to program irrigation
systems, many displays use irrigation terminology. In the following instructions, in
suchcasestheequivalentushingterminologyisshowninparentheses.
Caution: Leaving the infra-red connector connected to the built-in programming
interface can significantly reduce the battery life of the 9-volt batteries in the
programming interface and the rechargeable battery in the TBOS-II handheld.
TBOS-II Handheld Keys
HOME– press three seconds to turn handheld on.
ABC– press to choose from three available programs (to store a program when
preprogramming, or uploading a program to controller).
LEFT and RIGHT ARROWS– move curser left or right, also go back or forward one screen.
ON and OFF/+ and – /UP and DOWN ARROWS– Used to set flushing events on or off,
move selector up and down on screen, or increase or decrease duration and other values.
OK– press to make selection final.
TBOS-II Handheld Home Screen Menu
1) TBOS infra-red– Accessible only when connected to programming interface via the
IR cable: select to connect handheld to programming interface via infrared cable and
access programs on it, or to transfer programs from handheld to programming interface.
2) Templates (TBOS-II)– select to program handheld without connecting to
programming interface.
3) Settings– select to access and set time, date, and various other available user settings.

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First time use
1) Press HOME key for three seconds to turn on handheld.
2) Press RIGHT ARROW key or the OK key to access “Settings”
3) Use DOWN ARROW to select and set the following:
a) Date and Time
b) Contrast of the screen
c) Name of the handheld controller (can be assigned to a specific operator)
d) Language (English, French, Spanish, Italian, Dutch, Portuguese, Turkish, etc.)
Note: Programming instructions for all available languages are available by contacting
Mueller Co. at 800-423-1323.
Programming Flushing Schedule
NOTE: There are two ways to proceed– 1) select “TBOS-II infra-red”if IR cable is
connected to a TBOS-II programming interface to access, change or load programs
there, or 2) select “Templates (TBOS-II)” to create or change programs stored on the
handheld to load onto a programming interface at a later time (IR cable not used).
NOTE: The home screen for “TBOS-II infra-red”shows battery condition for
programminginterfaceandON/OFFstateofanycurrentoperationinprogress.
1) Press HOME key for three seconds to turn handheld on.
2) Press RIGHT ARROW key or the OK key to access“Settings”.
3) Use DOWN ARROW to select Templates” and press OK.
4) Use DOWN ARROW to select “Programs” and press OK
5) Use DOWN ARROW to select “Watering Days” (Days to Flush) and press OK.
6) Use UP/DOWN ARROWS to select one of the following:
a) Custom Cycle (Week): use RIGHT/LEFT ARROWS to move to days of the week,
use ON/OFF keys to highlight days on which to flush, then press OK to confirm
days when selections are complete.
b) Even Days: to Flush on even dates, press OK to set.
c) Odd Days: to Flush on odd dates including 31st, press OK to set.
d) Odd Days 31: to Flush on odd dated except 31st, press OK to set.
e) Cyclical: to Flush every “X” days, set “X” using ON/OFF keys (X=1 to 31), press OK
 toset;thensetstartdate“dd/mm/yyyy”usingON/OFF keys, press OK to set.
7) Use LEFT ARROW to navigate back to the program “Settings” menu.
8) Select “Start times”, press OK to set.
9) Use ABC to select program to be set up.
a) Set hours and minutes for each start time (up to 8 per program) using ON/OFF
keys, press OK to set each (hours are indicated using 24 hour clock). [When
exiting this screen, start times will automatically sort into chronological order.]
10) Use LEFT ARROW to navigate back to the program“Settings” menu.
a) Use DOWN ARROW to select“Valve Run Times”(Flush Duration), press OK to set.
NOTE:Althoughsixvalvesmaybeshownonscreen,onlyValve1isusedtomanagethe
Hydro-Guard® unit.
a) Use ON/OFFkeystoselectprogramA,Band/orC(oneormorecanbeassigned).
b) Then use ON/OFFkeystosetFlushduration(hoursand/orminutes)forprogram
just set, use LEFT/RIGHT ARROW keys to move between hours and minutes and
+ and – keys to set times (1 minute to 12 hours), press OK to set.

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Transmitting time, date and programs to programming interface, clearing/
checking programs, manual start
Connect handheld to programming interface using IR cable.
1) To transmit: from home screen, use DOWN ARROW to select “TBOS-II infra-
red” and press OK. TBOS-II handheld will receive data (settings) from built-in
programming interface.
2) Once data receipt is complete press RIGHT ARROW to move to “Settings” menu.
3) From “TBOS-II infra-red”settings screen select “Transmit” and press OK again.
When program to be transmitted appears, press OK to confirm.
4) To clear programs A, B, or C: from ”TBOS-II infra-red” welcome screen, use DOWN
ARROW to select “Clear Programs” and press OK, then select type of program to
clear and follow prompts.
5) To check programs A, B, or C: from ”TBOS-II infra-red” welcome screen, use
DOWN ARROW to select “Programs” and press OK, then select what is to be
checked and follow prompts.
Manual Flushing
Using TBOS-II handheld on the T-2 built-in programming interface (dark gray in color).
NOTE: Manual start cannot be initiated if there is no program in the programming
interface.
1) To start manual flushing from ”TBOS-II infra-red” welcome screen.
a) Use DOWN ARROW to select “Manual Watering” (Manual Flush) and press OK,
b) Select “Start Valve”(OpenControlValve)thenusingON/OFF keys select “Valve 1”
and press OK,
c) Use ON/OFF keys to set the manual Flush Time (1 minute to 12 hours) and press
OK to confirm. Flushing will start after a four (4) second delay.
Stop Manual Flush Sequence
1) Reconnect IR cable to built-in interface, then hold down HOME key on handheld.
2) Use RIGHT ARROW to select“TBOS-II infra-red”menu and select “Manual Watering.”
3) Select “Cancel Irrigation”toceasethemanualushsequence.

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The Problem: Failure to communicate.
The Likely Solutions:
1) The programming pod’s battery is low or out of power or the Handheld Programmer
is low or out of power; replace battery.
2)Youmayhaveanincorrectactuatorand/orprogramcode.Connectthehandheld
programmer via the cord, and set a new actuator code.
3) There might be a problem with a connection or solenoid. Perform an electrical
system check.
Special Notes:
The Pod’s internal memory lasts only 3 minutes. Any time the battery within the
Programming Pod dies, it is necessary to plug the Handheld Programmer directly into
the Pod and re-assign the Actuator ID and reprogram the Unit. While repeating the
programming steps is only a minor inconvenience, a proactive approach to battery
maintenancewillservetoalleviatethefrequencywithwhichthesestepsmustbe
completed.
Forallotherprogrammingquestions,pleaserefertotheHydro-Guard®Programming
Guide.Iftheinformationyourequireisnotavailabletherein,pleasecontactHydro-
Guard® Customer Service at [phone].

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Hydro-Guard® Options and Upgrades
The following is a brief overview and introduction to Hydro-Guard® Sampling, Options
and Upgrades.
Low Lead Brass Internal Components and Piping
S.M.A.R.T. Upgrade
Call 877-864-8500 and ask about upgrading your unit to our S.M.A.R.T. programming
system that allows communication through SCADA or tie in with a chlorine residual
monitor for complete automation.

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Technical Section

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Technical Section
Disassembly of the Hydro-Guard® HG-31 LongNeck™ Unit
Although the Hydro-Guard® Unit was delivered completely assembled, it may be
necessary or desirable to disassemble portions of the Unit, or the Unit in its entirety, in
ordertoallowforrequiredserviceandmaintenance.Ifdisassemblyisnecessary,please
follow the directions below. Always close the curb stop before working on the unit
making sure the supply line is shut off and secured.
A. HG-31 Standard Battery Replacement Instructions
1. Shut off water supply to unit.
2. Use HG-A2023 Security Tool to unlock and remove protective Exterior Housing Cover.
3. Unscrew protective cap from gray Programming Interface, which is located at top
of unit.
4. Extract battery harness and remove old battery (dispose of battery appropriately).
5. Connect fresh industrial grade 9-volt lithium or alkaline battery and reinsert it with
harness into Programmer.
6. Screw protective cap back into place and hand tighten securely.
7.UseHandheldControllertoresetallprogramsandassureushingsequenceis
correct prior to returning the HG-31 Unit to service.
8. Reinstall Exterior Housing Cover and restore water supply to unit.

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The HG-31 Unit is designed to operate unattended and with minimal need for service.
In the event it is necessary to service the flushing unit’s control valve, solenoid, or
any other below-grade component, or to reload the Dechlorination Chambers please
follow these instructions.
B. HG-31 Machine Disassembly
1. Shut off water supply to unit.
2. Use HG-A2023 Security Tool to unlock and remove protective Exterior Housing Cover.
3. Loosen, do not remove, two stainless steel nuts in Bracket holding Dechlorination
Chamber Covers in place.
4.RemoveBlackKnobfromPushRodthatispartofSamplingValveassemblyand
observe hole where rod passes though Erosion Controlling Ground Plate so that rod
can be properly guided through hole when reassembling unit.
5. Use HG-A104 Security Wrench to remove four security bolts from Ground Plate.
6. Lift upper assembly up and off pipe leading down into lower in-ground part of unit,
taking care not to stretch wiring and poly-tube sampling line.
7. Rotate downward two handles of Cam-Lock Release mechanism to disengage and
remove internal assembly.

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C. HG-31 Unit Reassembly
1. Return internal assembly to proper location and rotate upward two handles of
Cam-Lock mechanism.
2. Pull up on internal assembly to be sure it is locked in place (recommendation: use
a zip-tie to hold two Cam-Lock handles in position to assure they remain locked in
place during operation of the unit).
3. Gently lift upper section, making certain to not stretch wires or poly-tube, and
placeitoverpipe,SamplingValvepushrod,andloweritontotopofin-ground
section of unit.
4. Line up four holes of Ground Plate with brackets of in-ground Protective Sleeve.
Caution: do not rotate the plate more than 90° in either direction, which could
stretch wiring or poly-tube.
5. Reinstall four Security Screws and use HG-A104 Security Wrench to tighten them
securely.
6. Lower Dechlorination Chamber Bracket to original position and retighten two
nuts securely.
7. ReinstallKnobontoSamplingValvePushRod.
8. Check battery life of Battery in Programming Interface or on-board Programmer
(according to model of unit), replace and restore programming if necessary.
9. Align Lock on Exterior Housing Cover with Locking Bracket on lower assembly of unit
and reinstall Exterior Housing Cover (lock will engage when cover is properly seated).
10. Restore water supply to unit.

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D. Reloading Dechlorination Chambers
1. Follow instructions B1 thru B3 above.
2. Slide Bracket upward as far as possible and remove Dechlorination Chamber Covers.
3. Check for partially dissolved chlorine tablets or residues and clean the chamber
as needed
4. Insert up to four 3” chlorine tables in each chamber.
5. Reinstall chamber covers, lower bracket to secure them and retighten two nuts securely.
6. Follow instruction C9 above to reinstall Exterior Housing Cover, and restore water
supply to unit.

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The Hydro-Guard® Troubleshooting Guide
The Problem
The Hydro-Guard® Unit does not activate.
Possible Causes
1) Water pressure off or low 2) Batteries weak or dead 3) Connection loss from
controller to solenoid 4) Solenoid not working properly 5) Obstruction in flow of water
Try this Correction
1) Check if curb stop is open 2) Change batteries 3) Check connections for corrosion,
breaks, or lack of connection 4) Run an electrical systems check 5) Check to make sure
the flow control knob is open on the valve OR Check the pipes for obstructions OR
Check the valve
The Problem
The Hydro-Guard® Unit will not shut off.
Possible Causes
1) The solenoid is stuck in the open position 2) Batteries are weak or dead
3) Connection loss from battery box to solenoid 4) The solenoid is loose or there is
debris in the adapter 5) There is a hole in or debris around the diaphragm
Try this Correction
1) Run a manual flush for 1 minute 2) Change the batteries 3) Check the connections
for corrosion, breaks, or lack of a connection 4) Check the adapters and solenoid for
debris– Run the electrical systems check 5) Refer to valve troubleshooting for possible
corrective measures
The Problem
Water is found under the cap within the top access area of the Hydro- Guard® Unit.
Possible Causes
1) A damaged O-Ring on one or more of the four nipples under the diffuser head
maybeallowingleakage2)Theheightofallfour(4)nipplesmaynotbetheequal–
preventing a tight seal and allowing for leakage
Try this Correction
1) Remove diffuser and replace the damaged O-Ring(s) 2) Remove the diffuser and
adjusttheheightofthenipples,ensuringthattheyareequal

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HG-31 LongNeck™Unit Parts
Section

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546329
Assembly Drawing
546284
546330
546519
HG-S124 PHANTOM
HG-S128PHANTOM
546521
HG-S126PHANTOM
HG-S295PHANTOM
HG-S316PHANTOM
545729
545729
545738
HG-13105
HG-S325 PHANTOM