Mueller Hydro-guard 200 series Instruction Manual

TABLE OF CONTENTS PAGE

OPERATING INSTRUCTIONS MANUAL

WARNING:

1. 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.

2. Verify the drainage path prior to installation to ensure that pedestrian and ve-

hicular 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).

3. Never assemble, disassemble, or perform Hydro-Guard maintenance unless the

inuent supply valve has been closed, veried and secured, and internal piping

pressure has been relieved.

4. Always use all necessary safety equipment and follow all recommended pro-

cedures when installing, operating and maintaining the Hydro-Guard Automatic

Flushing Device.

5. Perform annual safety inspections and replace worn or defective parts.

6. Operate the Hydro-Guard Automatic Flushing Device only when fully installed and

correctly assembled.

CAUTION:

The recommended optimal operating pressure for a Hydro-Guard®Automatic Flushing

System is between 20 psi and 120 psi. In the event pressure may exceed 120 psi it

is recommended that a Pressure Regulating Valve be installed ahead of the

Hydro-Guard ushing system.

200 Series

Cold Climate

Sub-Surface

Discharge Unit

Installation Instructions 2

Programming Unit 3

Disassembly and Reassembly

Instructions 4

Options and Upgrades 5

Parts 6

F 12775 6/21

200 SERIES COLD CLIMATE SUB-SURFACE DISCHARGE UNIT

Installation Instructions

GENERAL

INSTALLATION

Site Evaluation

Each Hydro-Guard®System

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®Unit. Discharged water

flushed from the Hydro-Guard®

Unit must be routed away from

the device. It is recommended

that a 6" catch pipe (by others) be

installed inside of the 200 Series

Cold Climate's external cabinet.

The catch pipe shall be mounted at

of the internal flush

assembly. The

height of the 6" pipe

must be no less

than 3" from the

tip of the internal

flush assembly's

discharge point.

4. Connect the

utility's water system

to the Hydro-Guard®

Unit by means of

the 2" threaded

connection.

5. Backfill the hole

around under, and

inside of the Unit's

below grade base

with clean fill and/

or #57 stone.

Backfilling should be accomplished

in 6" compacted lifts. Check that

the Unit Is level.

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.

Overview

The Hydro-Guard®200 Series Cold

Climate Sub-Surface Discharge Unit,

the industry's premium patented,

programmable flushing apparatus,

is suitable for year-round use in

cold to extreme cold climates.

This Automatic Flushing System

has been designed, engineered,

and manufactured to provide

outstanding dependability and

performance.

Please read and retain this manual

for future training, reference,

troubleshooting, and maintenance.

Hydro-Guard® 200 Series Cold

Climate Unit

1. Remove the Hydro-Guard®Unit

from Its packaging and inspect for

possible damage during shipping.

2. Turn off service line feed.

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

approximately 1½ to 2 feet of

#57 stone below the base of the

200 Series Cold Climate to allow

for drainage. Then install non-

compacted clean bedding material

within the bottom of the hole.

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 top of the black base of the

enclosure should be approximately

1" above the final grade. Use

ground line marker on protective

in-ground sleeve to set height of

the internal assembly. Install the 6"

diameter discharge pipe opposite

least 3" under the discharge piping

of the 200 Series Cold Climate

(see Typical Installation illustration).

The 6" pipe shall be installed

a minimum of 24" below grade

before a 90-degree bend or pipe

size reduction. If desired, the 6"

pipe can be reduced to a 3" or 4"

pipe to continue the routing of the

flow to a final discharge point. The

recommended final discharge points

may include a storm drain, drainage

or retention pond, or a storm swale.

In the event static pressure is

routinely above 120 psi, Mueller

recommends installing a Pressure

Reducing Valve ahead of the Hydro-

Guard Flushing System."

7. Disinfect the Hydro-Guard®

Flushing Device in accordance

with the utility's policy. DO NOT

exceed the dosage and contact

times recommended by the

AWWA.

8. The Hydro-Guard® Automatic

Flushing Device may now be

programmed and placed into

service.

200 SERIES COLD CLIMATE SUB-SURFACE DISCHARGE UNIT

Programming Unit

PROGRAMMING HYDRO-GUARD UNIT FOR OPERATION

200 Series Cold Climate

(Requires Controller)

The BL-KR battery powered

irrigation module communicates

with the K-Rain BL Application on

a Smartphone or Tablet by using

Bluetooth SMART 4.0, (low energy)

on an iPhone with iOS version 7

minimum or an Android phone/

tablet with Marshmallow version 6.0

or higher.

Important

CAUTION: For use only with

9V DC Latching Solenoids. As

some solenoids will come from

the manufacturer with the plunger

already magnetically latched open,

some zones will default to OPEN.

Follow the start-up procedure

for systems with DC Latching

Solenoids. (Page 09)

CAUTION: For every change

to the program in the Mobile App,

you must exit back to the home

screen and tap the blue TRANSMIT

button (bottom right corner). The

Application aggregates changes

and transmits them to the

controller when you have finished

programming.

CAUTION: Programs A, B,

and C are independent programs,

including start times, run times,

watering days, and water budget.

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

8. Once the device is connected, it

will appear on the home screen when

you launch the Application.

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.

To add

another

controller, tap

the plus sign

in the upper

right hand

corner of the

home screen.

Application Home Screen:

Device Home Screen:

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.

6. The App will now search for

devices in range.

7. 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.

Disassembly and Reassembly Instructions

200 SERIES COLD CLIMATE SUB-SURFACE DISCHARGE UNIT

3. Using the a standard iOS

and Android cellular phone, and

the K-Rain App (free), begin

programmable procedure.

4. Conduct a system test upon

completion of installation. Run a

two minute manual flush test.

NOTE: Plunger inside solenoid

should be down when running and

up when off.

5. 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.

6. If test is successful re-assemble

unit.

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.

Although the Hydro-Guard®

200 Cold Climate Series 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.

200 Series Cold Climate Battery

Replacement

1. Remove protective external

cover and unlatch the cover of the

Internal protective sleeve.

2. Unscrew the cap off the

watertight housing of the integrated

Bluetooth programming interface.

Pull the battery box out of the

watertight housing. Replace 9-volt

battery with a 9-volt alkaline

battery.

3. Place the battery back into the

watertight integrated Bluetooth

programming interface making

certain to tighten the screw-on lid

until snug.

4. Relatch the cover of the internal

in-ground, protective sleeve and

return the external housing to its

proper location.

Disassembly

1. Shut off water supply to unit and

remove the green housing cover.

2. Unlatch hasp on hinged cover of

200 Series Cold Climate protective

ground sleeve.

3. Push both handles down to

release banjo coupling from the

bottom plate.

4. Pull straight up to remove the

Internal assembly.

Electrical System Check

1. Disassemble unit.

2. Unscrew Solenoid and be careful

NOT TO LOSE THE O-RING.

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.

Reassembly

1. Install internal assembly into

body, handles facing down. Set unit

straight down until it rests on the

male banjo coupling. Pull handles

up to lock Into place.

2. Return hinged cover to its correct

position and relatch the hasp lock.

Secure with a padlock if so desired.

3. Turn on the water supply to the

unit. Using the a standard iOS or

Android phone (recommend phone

be two years old or newer), and the

K-Rain App, conducted a 2 minute

manual flush test.

4. Install the housing cover over the

unit and lock in place.

200 SERIES COLD CLIMATE DISASSEMBLY AND REASSEMBLY INSTRUCTIONS

TOOLS NEEDED: HG-A2023 Security Tool, Phillips screwdriver, at-head screwdriver

Options and Upgrades

200 SERIES COLD CLIMATE SUB-SURFACE DISCHARGE UNIT

HYDRO-GUARD® FEATURES, OPTIONS AND UPGRADES

conservation.

Dechlorination (Included)

All Hydro-Guard®Units include

dechlorination systems.

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. This option is

available to be retrofitted onto the

200 Series Cold Climate

Sub-Surface Discharge Unit.

The following is a brief overview

and introduction to Hydro-Guard®

Sampling, Options and Upgrades.

Integrated Sample Station

(Included)

A standard feature on the 200

Series Cold Climate Sub-Surface

Discharge Unit, Hydro-Guard's

Sample Port allows the end user to

collect the sample. 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

S.M.A.R.T. Upgrade

The 200 Series Cold Climate is not

upgradeable to Smart technology;

however, call 800.423.1323 and

ask about upgrading to a Hydro-

Guard®S.M.A.R.T. 1200 Series

Flushing System that:

• 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, Wi-Fi, ethernet or

Blue Tooth®.

Parts

200 SERIES COLD CLIMATE SUB-SURFACE DISCHARGE UNIT

REPLACEMENT PARTS

ID PART # DESCRIPTION

1 HG-2201 UV Protective Housing

2 546553 Dechlorination Sub Assembly

3 HG-S124 Latching Sub Assembly

4 HG-A2006 TD Key

5 HG-123100 2" Composite Control Valve

6 HG-S125 2" Cam-lock

7 HG-S106 Bottom Plate Sub Assembly

8 FC200-BL Bluetooth Controller (Bury depth

required for actual part number)

HG-S106 200 Series Cold Climate

Bottom Plate Sub Assembly

HG-S124 Latching Sub Assembly

545729 Centering Star

HG-02125 ¼" x 1¼" Hex Bolt

HG-13176 ¼" x ¾" Phil Pan Screw

HG-S128 Relief Valve Sub Assembly

HG-S126 Insulation Star Sub Assembly

546549 200 Series Cold Climate

Top Plate Sub Assembly

HG-2201 DIV 1021-R

HG-21088 200 Series Cold Climate Name Plate

HG-V129 Silver Thermal Insulation

HG-A2006 TD Key

546372 200 Series Cold Climate Sample Port

HG-V116 Bulkhead Union Brass

HG-13198 ¼ – 20 Threaded Knob

HG-123108 ¼" x ¼" NPT Adaptor

546531 200 Series Cold Climate Sample Rod

HG-V105 ¼ Polyurethane tube

HG-S325 200 Series Cold Climate

Valve Sub Assembly

546550 200 Series Cold Climate

Outlet Sub Assembly

HG-S117 200 Series Cold Climate

Bottom Plate Connection

546522 200 Series Cold Climate

Below-Grade Housing

546526 200 Series Cold Climate Latching Rod

HG-S318 200 Series Cold Climate

Latching Solenoid

546535 200 Series Cold Climate Main Nipple

546553 200 Series Cold Climate

Dechlor Sub Assembly

NOTES

1.800.423.1323 – www.muellerwp.com – [email protected]

INTERNATIONAL – 1.423.490.9555 – www.mueller-international.com – international@muellercompany.com

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.

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).

LIMITED WARRANTY

This Hydro-Guard"" Automatic Flushing Device is warranted for one year from the date of delivery. Mueller 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. Call Mueller at 1.800.423.1323 during regular business hours, or contact Hydro-Guard at

www.Hydro-Guard.com for details on warranty service.

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