Motor City Wash Works ACCELERATOR TOPWL360BKS User manual

© Motor City Wash Works, Inc. 48285 Frank, Wixom Michigan 48393 U.S.A. Phone: [phone] ▪ Fax: [phone]
8MANULTOPWHL0001 12-9-20 www.motorcitywashworks.com 1
ACCELERATOR™ HORIZONTAL TOP WHEEL
INSTALLATION MANUAL
Part # TOPWL360BKS [ . . . . ]
( ALL COLORS )
TABLE OF CONTENTS
Equipment Specifications Page: 1
Equipment Features Page: 1
Suggested Tools and Installation Materials Page: 1
Installation Instructions Page: 2
Electrical Installations Page: 13
Optional Inverter Installations Page: 15
Pneumatic Installations Page: 19
Plumbing Installations Page: 21
Foamer Installation Page: 22
Start-Up Procedures Page: 23
Maintenance Page: 25
Troubleshooting………………………………………………………………………………………………………..Page: 28
Exploded Views………………………………………………………………………………………………………..Page: 31
Warranty………………………………………………………………………………………………………………..Page: 47
Equipment Specifications
Equipment Features
 Aluminum Structure Color Skinz™ Snap On Structure Wrap
 Available With Star Foam Wash Material
 Less Than 7 Feet of Tunnel Space required
 134” Overall Height
 Cleans Up to 200 Cars per Hour Line Speed
 Built-In Foam Streamer™ for added Show and Proper Lubrication
Suggested Installation Tools and Materials
  Hammer Drill with 5/8” Drill Bit  (12) Wedge Anchor Bolts 5/8” x 6”
 Sledge Hammer  Safety Goggles
 Set of Standard Combo Wrenches  Torpedo Level
 Measuring Tape  3/8” Polyflow Tubing
 1/2" Polyflow Tubing
ELECTRIC DRIVE
TOPWL360[ . . . . . . . ]
ELECTRICAL
CONTROL: 24VAC, 24VDC, 120 VAC, 3 WATTS UL® CERTIFIED
MOTOR: 1.5 HP 6.6-3.0 AMPS/208-460 VAC 3 PH
UL® RECOGNIZED, CSA CERTIFIED, CE MARK, IEC IP 55
PNEUMATICS 3 SCFM
WATER RECLAIMED OR FRESH:
2 GPM @ 40 PSI

© Motor City Wash Works, Inc. 48285 Frank, Wixom Michigan 48393 U.S.A. Phone: [phone] ▪ Fax: [phone]
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Notes and Safety Symbols
Where necessary, important points will be highlighted in this manual, using the following symbols:
NOTE: PROVIDES FURTHER INFORMATION!
WARNING! DANGEROUS SITUATION WHICH MAY CAUSE
EQUIPMENT DAMAGE, PERSONAL INJURIES, OR FATALITIES!
Always follow all notes, warnings, and instructions. Failure to do so may have serious consequences on
the overall performance of the equipment and/or the safety of the people working on the equipment!
Installation Procedures
  Upon receiving your MCWW equipment, open all boxes and crates, verify that you have all the required
components, that there is no damage to the equipment, and verify that you have all your installation
materials.
 Remove packaging material covering your ACCELERATOR™ TOP WHEEL and bring it to the wash, in the
area where it will be installed, and verify that the area is sufficiently large for the ACCELERATOR™ TOP
WHEEL WORKING ENVELOPE and DIMENSIONS (see Picture #1 though #4).
STOP! A PRECAUTION TO TAKE IN ORDER TO AVOID
EQUIPMENT MALFUNCTION OR ERROR!
PLEASE COMMUNICATE WITH YOUR LOCAL MOTOR CITY WASH WORKS
REPRESENTATIVE IF THERE IS ANY DAMAGE TO YOUR EQUIPMENT!

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Pic #1: Working Envelope for Accelerator™ With Foam
Pic #2: Working Envelope for Accelerator™ With Cross-Over ™

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Pic #3: Accelerator™ Overall Dimensions
Pic #4: Accelerator™ and Cross-Over™ Overall Dimensions
 FOR DRIVER’S SIDE MOUNTED TOP WHEEL:
Position the frame on the DRIVER’S SIDE OF THE CONVEYOR with the two arms pointing toward the
exit. Position the inside edge of the inside leg 21 INCHES OUTSIDE THE EDGE OF THE OUTSIDE
GUIDE RAIL (see Picture #5).

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 FOR PASSENGER’S SIDE MOUNTED TOP WHEEL:
Position the frame on the PASSENGER’S SIDE OF THE WASH BAY with the two arms pointing toward
the exit. Position the inside edge of the inside leg 112 INCHES OUTSIDE THE EDGE OF THE OUTSIDE
GUIDE RAIL (see Picture #6).
1'-9" [21"]
9'-4" [112"]
Pic #5: D/S Distance to Outside Guide Rail Pic #6: P/S Distance to Outside Guide Rail
Pic #7: Level Frame (1) Pic #8: Level Frame (2)
 Level the frame in both directions (see Picture #7 and #8). Then, secure to the floor using 5/8” x 6”
ANCHOR BOLTS (one for each floor mount hole).
 Attach the belt to the arm (see Picture #9).
 Locate the ADAPTOR PLATES and secure it on the arm as shown in Picture #10 or 11.

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DRIVER SIDE TOP WHEEL:
MOUNT THE ADAPTOR PLATES JUSTIFIED
TOWARDS THE RIGHT, AS SHOWN IN PIC #10.
PASSENGER’S SIDE TOP WHEEL:
MOUNT THE ADAPTOR PLATES JUSTIFIED
TOWARDS THE RIGHT AS SHOWN IN PIC #11.
Pic #10: Driver Side Adaptor Plates Assembly
Pic #11: Passenger Side Adaptor Plates Assembly
Pic #9: Connect the Belt

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 RAISE the Top Wheel arm with a LIFT to its highest position and lock the wheel arm from coming down by
using a large pry bar or the INCLUDED ALUMINUM HOLDING BAR and clamp below the arm.

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 Locate the DRIVE SHAFT ASSEMBLY and mount to the adaptor plates as shown in Pictures #12 and 13.
Pic #12: Driver’s Side Drive Shaft Assembly Mounting
Pic #13: Passenger’s Side Drive Shaft Assembly Mounting
 Locate the top wheel hub and LOOSEN THE MIDDLE CLAMP FASTENERS (see Picture below). Then,
slide the hub onto the drive shaft (see Picture #15 or 16).
Pic #14: Top Wheel Hub Assembly
Pic #15: Driver’s Side Hub Assembly
SECURE THE DRIVE
UNIT TO THE ARM

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Pic #16: Passenger’s Side Hub Assembly
 Tighten all the clamp fasteners evenly starting from the middle toward the ends.
Pic #16: Passenger Side Hub Assembly
 Remove the compression plates at the end of the hub and slide a 20” STAR FOAM BUN ONTO THE HUB
(see picture #18). Follow with four 10” STAR FOAM BUNS and complete with the last 20” BUN. Finish by
adding as many 12" foam spacers necessary to get at least 2-1/2" of compression. Reinstall the two
compression plates (see Picture #19).
Pic #17: Driver’s Side Compression Plates
TIGHTEN
STOP!
IT IS IMPORTANT THAT THE FASTENERS ARE
TIGHTENED EVENLY. FAILURE TO DO SO MAY CAUSE THE TOP
WHEEL BRUSH TO WOBBLE WHEN RUNNING AND MAY LEAD
TO PREMATURE WEAR OF YOUR TOP WHEEL.

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Pic #18: Slide in 20” Bun
Pic #19: Star Foam Top Wheel
 Raise the Top Wheel arm with a FORK LIFT TRUCK or a GENIE LIFT™ to its highest position, which will
result in the COUNTERWEIGHT ARM resting at its lowest position. Your top wheel comes with NINE 1”
COUNTERWEIGHTS and FOUR 1/4" COUNTERWEIGHTS. Add five of the 1” counterweights to the top
slot and four in the bottom slot. Then, add two of the 1/4" counterweights in the TOP or BOTTOM slot to
the counterweight arm box (see picture #20 and 21). Keep the remaining counterweight for future usage.
ADD
SPACERS IF
NEEDED

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Pic #20: Counterweights
NOTE:
YOU MAY LEAVE THE TOP WHEEL BRUSH DOWN AND LOAD
THE COUNTERWEIGHTS, ONE-AT-A-TIME USING A STEP LADDER.
Pic #21: Counterweight Arm
(5) 1” COUNTERWEIGHT

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 After you have secured the counterweights, manually raise and lower the top wheel and confirm that the
wheel is PROPERLY BALANCED. To do so, move the arms and make sure that the brush remains still at
any position. Remove or add more weight if needed to balance the wheel.
 Locate the boxes containing the COLOR SKINZ™ covers and install on each of the legs and arms (see
below).
Pic #22 Color Skinz™ Pic #23 Color Skinz™
STOP!
YOU MAY NEED TO ADD SOME ADDITIONAL COUNTERWEIGHTS
AFTER THE TOP WHEEL HAS BEEN RUN; THE FOAM WILL
ABSORB SOME WATER AFTER A BREAK- IN PERIOD, WHICH
MAKES THE TOP WHEEL HEAVIER.
TO BALANCE THE TOP WHEEL, USE THE SPARE
COUNTERWEIGHTS
SUPPLIED WITH YOUR ACCELERATOR™ TOP WHEEL.
SELECT THE
PROPER COLOR
SKINZ™ COVER.
SNAP ONE SIDE OF
THE LIP, SLIDE
THE COVER
AROUND THE LEG
AND FINALLY
SNAP THE
SECOND LIP PAST
THE EXTRUSION
EDGE (see Picture
#23)

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Electrical Installation :
 If you have purchased the ELECTRIC DRIVE ACCELERATOR™ TOP WHEEL, bring a cable from a
separate MOTOR SOFT STARTER unit to the MOTOR CONNECTION BOX (see Picture #24). Then,
connect the motor cable to the 1.5 HP DRIVE MOTOR. The motor has to be protected with an OVERLOAD
RELAY WHICH NEEDS TO BE SET AT THE MOTOR-RATED FULL LOAD CURRENT FOR THE
PROPER VOLTAGE.
 Connect the air valve to an output from the car wash controller in series with the N.O. AUXILIARY
CONTACTS of the starter unit like shown on picture #24.
OUTPUTS 120VAC ONLY
CAR WASH CONTROLLER
NEUTRAL
Pic #24 Motor Starter Connections
NOTE:
ALWAYS CONNECT THE MOTOR TO A SOFT STARTING
DEVICE (SOFT STARTER OR VFD). NOT DOING SO WILL CAUSE SERIOUS
DAMAGES TO YOUR EQUIPMENT AND
VOID YOUR WARRANTY!
NOTE:
CONNECT THE AIR VALVE IN SERIES WITH
THE SOFT STARTER’S AUXILIARY CONTACTS.
NOT DOING SO MAY LEAD TO SERIOUS DAMAGE TO
YOUR EQUIPMENT IN THE EVENT THE MOTOR IS NOT
RUNNING WHEN THE BRUSH IS DOWN.
24 OR 120VAC
SOFT STARTER

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Pic #25 Connection Box
WARNING!
EACH MOTOR HAS TO BE
PROTECTED WITH AN
OVERLOAD RELAY
SET AT THE MOTOR RATED
FULL LOAD CURRENT
4.9 AMPS @ 208 VAC - 3PH
4.8 AMPS @ 230 VAC – 3PH
2.4 AMPS @ 460 VAC – 3PH
AIR VALVE
CONNECTION BOX
24 OR 120VAC
3 WATTS
Pic #26 Motor Connection
MOTOR
CONNECTION BOX
1.5HP/208
-
460VAC/3PH

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Optional Top Wheel Inverter (VFD):
 If you have purchased the optional TOP WHEEL INVERTER (see Picture #27A and B below) YOU DO
NOT NEED a separate overload relay for motor protection: The inverter is set at the factory and provides
proper protection to operate the Top Wheel motor for selected voltage of 208-230VAC and 480VAC/3PH.
INTERLOCK
14 12 1 1
A2 A1
A1
A2 11
12 14
EL KO
20A D20A D
WITH AIR V ALVE
SPIN COMMAND
(FRWD SIGNAL)
14 12 1 1
A2 A 1
A1
A2 11
12 14
EL KO
15A D15A D15A D
INTERLO CK
WITH AIR VALVE
SPIN CO MMAND
(FRWD SIG NAL)
Pic #27A: MTRSTRSNGVFD001-208-230VAC Pic #27B: MTRSTRSNGVFD005-480VAC
 Connect the motor terminals (T1-T2-T3) to the motor connection box (see Picture #28A-D).
 Connect the SPIN COMMAND INPUT to ONE OUTPUT FUNCTION (120VAC) from your car wash
controller (see Picture #28(A-D).
 Finally, connect the air valve to ONE OUTPUT FUNCTION through the INTERLOCK SAFETY
CONTACTS terminals (see Picture #28A-D).
14 12 11
A2 A1
A1
A2 1 1
1214
E LKO
L1L2
T1 T2 T3
VF D1
T R1
A1 A2
R1
C
R1
A
2 0A D2 0A D
CB1
AC OR DC OUTPUTS
CAR WASH CONTROLLER
NEUTRAL
14 12 11
A2 A1
A1
A2 1 1
12 1 4
ELKO
L1L2
T1 T2 T3
VF D1
TR1
A1 A2
R1
C
R1
A
1 5A D1 5A D15A D
CB1
L3
AC OR DC OUTPUTS
CAR WASH CONT ROLLER
NEUTRAL
Pic #28A: 208-240V Inverter Connection Diagram Pic #28B: 480V Inverter Connection Diagram

© Motor City Wash Works, Inc. 48285 Frank, Wixom Michigan 48393 U.S.A. Phone: [phone] ▪ Fax: [phone]
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FIELD WIRING TERMINAL TORQUE:
CONTROL WIRING
ATV VFD OUTPUT TERMINALS:
TESY S STARTER OUTPUT TERMINALS:
ATS SOFT START OUTPUT TERMINALS:
4 IN/LBS
7 IN/LBS
15 IN/LBS
15 IN/LBS
MCWW 3PH MOTOR FULL LOAD CURRENT @ 208VAC
1HP (SIDE BRUSHES)
1-1/2HP (MITTER, TOP WHEEL, BULLDOG)
3HP (HYDRAULIC UNIT, CONVEYOR)
3.2A
5.8A
11A
MTRSTRSNGVFD001
FIELD WIRING TERMINAL TORQUE:
CONTROL WIRING
ATV VFD OUTPUT TERMINALS:
TESYS STARTER OUTPUT TERMINALS:
ATS SOFT START OUTPUT TERMINALS:
4 IN/LBS
7 IN/LBS
15 IN/LBS
15 IN/LBS
MCWW 3PH MOTOR FULL LOAD CURRENT @ 480VAC
1HP (SIDE BRUSHES)
1-1/2HP (MITTER, TOP WHEE L, B ULLDOG)
3HP (HYDRAULIC UNIT, CONVEYOR)
2.1A
3.0A
4.8A
MTRSTRSNGVFD005
Pic #28C: 208-240V Inverter Wiring Diagram Pic #28D: 480V Inverter Wiring Diagram
 Your Motor City Overdrive inverter control box comes pre-programmed. Use one of the two “Inverter
Parameters” list below to verify the VFD parameters if necessary.

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MENU CODE DESCRIPTION
FACTORY
SETTING
TOP
WHEEL MITTER AROUND LSW BULLDOG
STANDARD MOTOR FREQUENCY (Hz)
50.0 60.0
RATED MOTOR POWER ON MOTOR NAMEPLATE (HP)
DRIVE
RATING 1.5 1.5 3.0 2.0 3.0
RATED MOTOR VOLTAGE ON MOTOR NAMEPLATE (V)
208
RATED MOTOR CURRENT ON MOTOR NAMEPLATE (A)
5.8 5.8 11.6 6.4 11.6
RATED MOTOR FREQ. ON MOTOR NAMEPLATE (Hz)
50.0
RATED MOTOR SPEED ON MOTOR NAMEPLATE (RPM)
1740
ACCELERATION TIME (SEC)
3.0 3.0 2.0 1.5 0.0 40 30
MOTOR FREQUENCY AT MINIMUM SPEED (Hz)
50.0 70.0
2 OR 3 WIRE CONTROL 2 WIRE TYPE OF CONTROL
FORWARD DIRECTIONAL COMMAND MOTOR FREQUENCY AT MAXIMUM SPEED (Hz)
60.0 60.0 60.0 60.0
DRIVE
RATING
DRIVE
RATING
60.0
DRIVE
RATING
60.0 60.0 60.0 60.0
1740 1740 1740 1740
3.0 3.0
40 40 40
60.0 70.0 70.0 70.0
(2 WIRE) (2 WIRE) (2 WIRE) (2 WIRE) (2 WIRE) (2 WIRE)
2
SEC
2
SEC
(LEVEL) (LEVEL) (LEVEL) (LEVEL) (LEVEL) (LEVEL)
(LI-1) (LI-1) (LI-1) (LI-1) (LI-1) (LI-1)
RELAY R1 CONFIGURATION
TYPE OF STOP
PROFI LE
(VFD RUNNING) (VFD running) (VFD running) (VFD running) (VFD running) (VFD running)
(FREEWHEEL) (FREEWHEEL) (FREEWHEEL) (FREEWHEEL) (FREEWHEEL) (FREEWHEEL)
(I/O PROFILE) (I/O PROFILE) (I/O PROFILE) (I/O PROFILE) (I/O PROFILE) (I/O PROFILE)2
SEC
208 208 208 208
CURRENT SETTI NG OF VFD AND MOTOR OVERLOAD (A)
OVERLOAD SETTING
FVD
MOTOR
N/A
23
N/A
N/A
6
4
6
23 23 23 23
DRIVE
RATING
MOTOR THERMAL PROTECTION MOTOR FLA*SF (AMPS)
7713 8 13
CONTROL REFERENCE (FREQ CONTROL) (V.A.I. DIAL) (V.A.I. DIAL) (V.A.I. DIAL) (V.A.I. DIAL) (V.A.I. DIAL) (V.A.I. DIAL)
Pic #28E: 208V Inverter Parameters

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MENU CODE
DESCRIPTION
FACTORY
SETTING
TOP
WHEEL MITTER AROUND
ROCKERZ
LSW BULLDOG
STANDARD MOTOR FREQUENCY (Hz)
50.0 60.0
RATED MOTOR POWER ON MOTOR NAMEPLATE (HP)
DRIVE
RATING 1.5 1.5 3.0 2.0 3.0
RATED MOTOR VOLTAGE ON MOTOR NAMEPLATE (V)
460
RATED MOTOR CURRENT ON MOTOR NAMEPLATE (A)
2.80 2.80 5.50 3.4 5.10
RATED MOTOR FREQ. ON MOTOR NAMEPLATE (Hz)
50.0
RATED MOTOR SPEED ON MOTOR NAMEPLATE (RPM)
1740
ACCELERATION TIME (SEC)
3.0 3.0 2.0 1.5
0.0 40 30
MOTOR FREQUENCY AT MINIMUM SPEED (Hz)
50.0 70.0
2 OR 3 WIRE CONTROL 2 WIRE TYPE OF CONTROL
FORWARD DIRECTIONAL COMMAND MOTOR FREQUENCY AT MAXIMUM SPEED (Hz)
60.0 60.0 60.0 60.0
DRIVE
RATING
DRIVE
RATING
460 460 460 460
60.0
DRIVE
RATING
60.0 60.0 60.0 60.0
1740 1740 1740 1740
3.0 3.0
40 40 40
60.0 70.0 70.0 70.0
(2 WIRE) (2 WIRE) (2 WIRE) (2 WIRE) (2 WIRE) (2 WIRE)
2
SEC
2
SEC
(LEVEL) (LEVEL) (LEVEL) (LEVEL) (LEVEL) (LEVEL)
(LI-1) (LI-1) (LI-1) (LI-1) (LI-1) (LI-1)
RELAY R1 CONFIGURATION
TYPE OF STOP CONTROL REFERENCE (FREQ CONTROL)
PROFILE
(VFD RUNNING) (VFD running) (VFD running) (VFD running) (VFD running) (VFD running)
(FREEWHEEL) (FREEWHEEL) (FREEWHEEL) (FREEWHEEL) (FREEWHEEL) (FREEWHEEL)
(V.A.I. DIAL)
(I/O PROFILE)
(V.A.I. DIAL)
(I/O PROFILE)
(V.A.I. DIAL)
(I/O PROFILE)
(V.A.I. DIAL)
(I/O PROFILE)
(V.A.I. DIAL)
(I/O PROFILE)
(V.A.I. DIAL)
(I/O PROFILE)
2
SEC
CURRENT SETTING OF VFD AND MOTOR OVERLOAD (A)
OVERLOAD SETTING
FVD
MOTOR
N/A
9
N/A
N/A
2.5
1.6
9 9 9 9
2.5
Pic #28F: 480V Inverter Parameters

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Pneumatic Installation:
 Your MCWW ACCELERATOR™ TOP WHEEL requires a supply of compressed air capable of 3 SCFM @
100 PSI.
WARNING!
IT IS IMPERATIVE TO SUPPLY THE ACCELERATOR™ PNEUMATIC
SYSTEM WITH CLEAN, DRY, COMPRESSED AIR.
ANY AMOUNT OF MOISTURE, VAPORIZED OIL OR ANY
OTHER IMPURITIES WITHIN THE MAIN AIR SUPPLY MAY
AFFECT THE PERFORMANCE OF THE EQUIPMENT
AND LEAD TO PREMATURE WEAR OR MAJOR DAMAGE
TO THE ACCELERATOR™ DELIVERY SYSTEM OR ITS COMPONENTS.
 Bring a 3/8” OD polyflow tubing air line from the main compressed air supply to the AIR PANEL MAIN AIR
SUPPLY FITTING (see Picture #35).
20-45 PSI
80-100 PSI
h ori zon tal to p wheel
Accelerator
TM
8 D CA L T P WP NL0011
SUPPLY
MAIN AIR
1 20 VAC
P ENE TRA TION
TOP WHEEL
VALVE
3 P OS ITION
D OWN VA LVE
TOP WHEEL
Pic #35 Air Panel
WHEEL PENETRATION
REGULATOR 20-40 PSI
TOP WHEEL DOWN
AIR VALVE MANUAL
OVERRIDE BUTTON
MAIN AIR SUPPLY
REGULATOR 80
-
100
(OPTIONAL) 3 POSITION
AIR VALVE MANUAL
OVERRIDE BUTTON
MAIN AIR SUPPLY
100-125 PSI
BLUE – TO ROD
END OF CYLINDER
YELLOW – TO
CYLINDER END
BLACK – TO 3
POSITION CYLINDER
END