Mueller HYDRO-GUARD HG-8 Instruction Manual

TABLE OF CONTENTS PAGE
OPERATING INSTRUCTIONS MANUAL
WARNING:
1. Read and follow instructions carefully. Proper training and periodic review
regarding the use of this equipment is essential to prevent possible serious injury
and/or property damage. The instructions contained herein were developed for
using this equipment on ttings manufactured by Mueller Co. only, and may not be
applicable for any other use.
2. DO NOT exceed the pressure ratings of any components or equipment. Exceeding
the rated pressure may result in serious injury and/or property damage.
3. Safety goggles and other appropriate protective gear should be used. Failure to do
so could result in serious injury.
HG-8
Warm Climate
Flushing System
Installation Instructions 2 - 3
Programming Unit 3 - 4
Assembly, Disassembly, &
Maintenance Instructions 5
Troubleshooting 6
Upgrades & Battery Replacement 7
Parts 8
F 13827 2/21
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2
HG-8 WARM CLIMATE FLUSHING SYSTEM
Installation Instructions
GENERAL
INSTALLATION
Please read and retain this
manual. It will be helpful for
future reference, training,
troubleshooting, and maintenance.
Site Evaluation
Each Hydro-Guard Unit 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
Overview
The Hydro-Guard HG-8 Warm Climate
Unit, is the industry’s only Sub-
Surface Discharge, programmable
flushing apparatus (patent pending).
This Unit is suitable for year-round
use in warm to moderate climates.
This Automatic Flushing System has
been designed, engineered, and
manufactured to provide outstanding
dependability and performance.
Hydro-Guard HG-8 Warm Climate
Flushing Unit
The Hydro-Guard HG-8 Warm
Climate Flushing System is
housed in a Mueller Meter Box
that is approximately 33-7/8"
long x 23-3/8" wide x 24" deep.
The wall thickness is 1/2". The
box is constructed with low lead
NTP male threads and is to be
placed by the contractor at a
location agreed upon by the end
user. The box features brass
inlet and outlet connections that
will route water from the water
utility’s potable water distribution
line through the HG-8’s flushing
components, and discharge
through a discharge service
routed to an acceptable point of
discharge (i.e., a storm sewer,
swale, storm pond, etc.).
WARNING: Proper lifting,
loading / unloading tools
and techniques must be followed
when handling this device.
Damage to working components
can occur if dropped.
1. Remove the Hydro-Guard Unit
from its packaging and inspect for
possible damage during shipping.
2. Turn off the service line feed.
should be reviewed. The drainage
pattern must permit discharged water
to flow away from the Hydro-Guard
Unit. Discharged water flushed from
the Hydro-Guard Unit must be routed
away from the device. (see Typical
Installation illustration).
The recommended final discharge
points may include a storm drain,
drainage or retention pond, or a
storm swale.
!
3. 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,
place non-compacted clean bedding
material within the bottom of the
hole. Provide a bed of crushed
gravel approximately 6 inches thick
or place bricks or cement blocks
below the pit to allow for drainage
and provide support.
4. Slowly lower the Hydro-Guard
HG-8 Warm Climate Flushing System
into place, pressing it firmly into the
non-compacted bedding material
within the bottom of the hole.
5. Bury the pit so the top edge is at
ground level.
See detail A
Detail A
Scale 0.375
2" Low
Lead Brass
Piping
2" Double
Check Backflow
Dechlorination
Bluetooth Controller
Adjustable
Flow 2"
Valve
Sample Port
Camlock
Release
2" NPT
Thread
(Outlet)
2" NPT Thread
(Inlet)

3
HG-8 WARM CLIMATE FLUSHING SYSTEM
Installation Instructions & Programming Unit
INSTALLATION - (CONTINUED)
PROGRAMMING HYDRO-GUARD UNIT FOR OPERATION
disturb the connection to the pit
and possibly overtightened the
connection or otherwise affect the
contractor’s proper installation of
the pit itself.
9. Backfill the hole around the
flushing device with clean fill and/
or #57 stone. Backfilling should be
accomplished 12 inches at a time
and hand-tamp each layer until the
service grade is restored.
10. After installation is complete,
sod the area around the Hydro-
Guard Unit or take other steps in
order to prevent erosion.
11. Disinfect the Hydro-Guard
6. Install the top of the meter
box level with existing grade and
ensure the meter lid is level with
existing grade.
7. Place the pit in the excavated
area and connect the inlet piping.
Hand-tighten the fitting to the pit,
then turn two full turns with a
wrench. This will result in a leak-
tight connection, without placing
undue stress on the pit piping.
8. We recommend installing
approximately 10' of pipe to the
outlet connection so the plumber
that is completing the service
installation does not have to
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.
12. The Hydro-Guard Automatic
Flushing Device may now
be programmed.
13. Once programming has been set,
install lid.
WARNING: We do not
recommend the following:
1) Dumping fill material on top of the
pit; 2) Using machinery to
compact backfill.
!
1. Install the App:
From the App Store
or Google Play
Install the free K-RainBL App:
2. Install a 9 Volt Battery in
the Controller:
Unscrew the cap, remove the
seal and fasten the battery to the
correct terminals. Replace the
seal and cap and hand-tighten the
cap to ensure it seals.
NOTE: Before you launch the App, you
will need to enable locations services
on your phone/tablet in order for the
App to geolocate your device during
installation. On Android, location
services must be enabled in order
for the App to connect to the BL-KR
device.
3. Launch the application on your
Smartphone or Tablet.
4. Associate the controller with
your phone by tapping the
Add a Controller button.
5. The app will now ask what type
of Bluetooth device you would
like to add:
NOTE: The BL-KR V1.0 and
BL-KR V2.0 have identical
hardware and software
configurations.
The only distinction is the
outside plastic housing.

4
Programming Unit
HG-8 WARM CLIMATE FLUSHING SYSTEM
1. The App will now search for
devices in range.
2. Choose the Controller. The
serial numbers that populate
the device list can be found
on the label located on the
back of the controller housing
with the designation “Default
name.” The App will indicate
that it is in the process of
connecting.
3. Once the device is connected,
it will appear on the home
screen when you launch the
Application.
To add another controller,
tap the plus sign in the
upper right hand corner
of the home screen
NOTE:
You can associate up to 400 devices with the K-Rain BL-KR App. The number of devices is limited to the internal
memory on the Smartphone/Tablet.
Application Home Screen Device Home Screen

5
Disassembly / Reassembly Instructions
HG-8 WARM CLIMATE FLUSHING SYSTEM
TOOLS NEEDED: Philips screwdriver, at-head screwdriver, HG-20087 T-handle wrench
HG-8 DISASSEMBLY AND REASSEMBLY INSTRUCTIONS
4. To prevent the loss of the
solenoid plunger and spring, place
an object or have a finger over
the plunger of the solenoid. Allow
the plunger enough space to kick
out of the solenoid body into the
object or finger hovering over it.
5. If test is successful, return
the flush / meter assembly to its
operating position below grade.
6. Return insulation pad and cast
iron meter lid to their
proper positions.
If everything checks out, the
electrical system is in
working order.
Valve Disassembly and Check
1. Remove six (6) bolts from
top cover.
2. Slowly pull cover off the valve.
3. Remove rubber diaphragm and
inspect for holes or worn areas.
4. Be certain to avoid contacting
the EPDM rubber diaphragm with
pipe putty. Pipe putty can cause
the rubber to thin out and leak.
5. Remove the valve screen plug
on the lower half of the valve body.
Be careful not to exert too much
force when pulling plug out.
6. Check for debris in the valve
screen on the inlet side with the
lower half of the valve body by
removing the valve screen plug.
7. Return valve plug to its
proper location when debris screen
is cleared.
8. Replace the top cover back onto
the diaphragm – make sure to line
up the openings in both.
9. Match up the top cover of the
valve with the bottom portion.
The arrows have to align on both
portions.
10. Replace the bolts and
tighten down.
Although the Hydro-Guard HG-8
Warm Climate Sub-Surface
Unit was delivered completely
assembled, it may be necessary
and/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.
Disassembly
1. Shut off water supply to
the unit and remove the green
housing cover.
2. Remove the composite lid
of HG-8 protective ground
sleeve vault.
3. Backup to stress point then
push down on the camlock
release handles to disengage
the camlocks prior to lifting the
flushing components out of
the device.
4. Raise and remove the flushing
system assembly out of the
meter box.
5. Modular design of valve and
double check valve allow for
service to be completed without
removal of the devices’ bodies
from the piping assembly.
Electrical System Check
1. Pull internals of HG-8 out of
in-ground protective vault.
2. Unscrew solenoid from valve –
be careful to not drop the
solenoid plunger and spring into
in-ground housing.
3. Using the Bluetooth Controller,
run a 2 minute manual flush
seequence.
NOTE: Plunger inside solenoid
should be down when running and
up when off.
WARNING: Avoid overuse of
pipe sealant and never allow
sealant to come into contact with
EPDM rubber diaphram.
Reassembly
1. If any disassembly has been
conducted of the control valve and/
or double check valve, verify that all
bolts are properly tightened. Check
assemblies for leakage prior to
lowering flushing / metering assembly
back into position below grade.
2. Using lifting holes and/or lifting
strap on steel plate, lower flushing
assembly below grade by slowly
lowering the steel frame to the lower
part of the in-ground protective
housing (DO NOT apply excessive
force to assembly). Use Guide in
meter box to allign internols.
3. Once lowered back into the
pretective vault, lock the internals
in place by pulling up on camlock
handles.
4. Turn water supply to the unit
on. Using the controller, run a two
minute manual flushing procedure
to confirm all components
are operational.
5. Return insulation pad and lid to
their proper location.
!

6
Troubleshooting
HG-8 WARM CLIMATE FLUSHING SYSTEM
TROUBLESHOOTING THE PROGRAMMER
TROUBLESHOOTING THE UNIT
• Run a manual flush and
confirm the solenoid
plunger is kicking out and
pulling back in by listening
for a click.
• Check to make sure the
flow control knob is open
on the valve. Check the
pipes for obstructions.
Check the valve for debris
and/or damage.
The Hydro-Guard Unit will not
shut off:
Possible Causes
• The solenoid is stuck in the
open position or debris is
interferring with the plunger.
• Batteries weak or dead.
• Connection loss from
battery box to solenoid.
• The solenoid is loose or
there is debris in the adapter.
• There is a hole in or debris
If your Hydro-Guard Unit does
not activate:
Possible Causes
• Water pressure off or low.
• Batteries weak or dead.
• Connection loss from
controller to solenoid.
• Solenoid not
working properly.
• Obstruction in flow of water.
• Obstruction in double
check valve.
Try this Correction
• Check if curb stop is open.
• Change batteries.
• Check connections for
corrosion, breaks, or lack
of connection.
• Check backflow
preventer (follow
manufacturer’s instructions).
around the diaphragm.
Try this Correction
• Run a manual flush for
2 minutes.
• Change batteries.
• Check connections for
corrosion, breaks, or lack
of connection.
• Check the adapters and
solenoid for debris – Run the
electrical systems check.
• Refer to valve
troubleshooting for possible
corrective measures.
PROBLEM CAUSE SOLUTION
Controller does not flush
as desired
Water at main water supply is
shut off
Battery dead Replace battery
Battery dead Replace battery
Controller improperly programmed Check program and clock settings
Controller set to OFF Set controller to desired program
Blank display
Water does not turn off Overlapping programming Review all programming and edit
any program that is in conflict with
desired off schedule
Clear all programming in memory
and reset
Programmer not communicating Check Programming
Run Manual On / Off with solenoid
removed from valve (hold finger
or object over solenoid plunger to
prevent plunger from dislodging
from solenoid body)
Check wiring for damage and
connectors to ensure proper
connection (red to red & black
to black)
Check main supply valve

7
Upgrades & Battery Replacement
HG-8 WARM CLIMATE FLUSHING SYSTEM
HYDRO-GUARD FEATURES, UPGRADES AND SAMPLE COLLECTION
BATTERY REPLACEMENT
Dechlorination
The Hydro-Guard HG-8 Warm
Climate Unit is equipped
with a dechlorination system.
Dechlorination takes place as
a portion of the discharged
water passes through a housing
containing either sodium sulfite
or ascorbic acid tablets. This
action creates a concentrated
dechlorination solution that
then mixes with the non-directly
treated portion of the discharge to
effectively dechlorinate the entire
discharge volume.
S.M.A.R.T. Monitoring and
Flush Management
The Hydro-Guard HG-8 can not be
upgraded to S.M.A.R.T. technology.
To monitor water quality, conditioned
in real time, Mueller offers a variety
of S.M.A.R.T monitoring and flushing
systems.
5. Place the battery back into the
watertight integrated Bluetooth
programming interface making
certain to tighten the screw-on lid
until snug.
6. Return the internals of the HG-8
to its proper location.
The following is a brief overview and
introduction to our options.
Integrated Sample Station
The HG-8 Warm Climate Sub-Surface
Discharge Unit, features a Sample
Port quick connect that allows the
end user to collect a sample from
the HG-8 installation site. To collect
a sample from the sample quick
connect the HG-S116B Portable
Sample Valve will be required.
(Recommendation: one HG-S116B
per every five HG-8 units) You may
wish to run a brief manual-mode
flush prior to the collection in order
to ensure water indicative of the
main-line water quality is being
sampled. Generally a two-minute
flush is sufficient. Track your
residual levels and alter flushing
frequency and/or duration in order
to maximize water conservation.
1. Remove composite or cast iron
lid and insulation pad.
2. Locate the controller and its
battery compartment.
3. Be sure to tighten battery
compartment cap securely before
returning unit to service.
4. Programming
a. HG-8 Bluetooth (BL) –
Unscrew the grey cap off
the watertight housing of
the integrated programming
interface. Pull the battery
box out of the watertight
housing. Replace 9-volt
battery with a 9-volt
alkaline battery.
The Hydro-Guard S.M.A.R.T.
flushing system:
• Monitors chlorine levels (total
or free).
• Flushes distribution line when
residual disinfectant drops below
acceptable levels.
• Monitoring of pH, flow,
temperature or turbidity available.
• Two-way real-time communication
via cellular, wifi, ethernet
or BlueTooth®.

8
Parts
HG-8 WARM CLIMATE FLUSHING SYSTEM
REPLACEMENT PARTS
ID DESCRIPTION
1Meter Vault
2 Male Camlock
3Bluetooth Controller Interface
4Dechlorination System
5Female Camlock
62" Double Check Valve
7 Sample Quick Connect
8 2" Control Valve
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1.800.423.1323 – www.muellerwp.com – [email protected]
INTERNATIONAL – 1.423.490.9555 – www.mueller-international.com – [e-mail]
Mueller refers to one or more of Mueller Water Products, Inc. a Delaware corporation (“MWP”), and its subsidiaries. MWP and each of its
subsidiaries are legally separate and independent entities when providing products and services. MWP does not provide products or services to
third parties. MWP and each of its subsidiaries are liable only for their own acts and omissions and not those of each other. MWP brands include
Mueller®, Echologics®, Hydro Gate®, Hydro-Guard®, HYMAX®, Jones®, Krausz®, Mi.Net®, Milliken®, Pratt®, Singer®, and U.S. Pipe Valve & Hydrant.
Please see muellerwp.com/brands and krauszusa.com to learn more.
© 2021 Mueller Water Products, Inc. All Rights Reserved. The trademarks, logos and service marks displayed in this document are the property of Mueller Water Products, Inc., its afliates or
other third parties. Products marked with a section symbol (§) are subject to patents or patent applications. For details, visit www.mwppat.com. These products are intended for use in potable
water applications. Please contact your Mueller Sales or Customer Service Representative concerning any other application(s).
See detail A
Meter Vault
Detail A
Scale 0.375
2" Low Lead
Brass Piping
2" NPT
Thread
(Outlet)
2" NPT Thread
(Inlet)
1
5
5
3
3
3
7
2
6
6
6
4
4
4
8
8