Mueller Hydro-Guard HG-8 Cold Climate 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
Cold Climate
Flushing System
Installation Instructions 2 - 3
Programming Unit 3 - 6
Assembly, Disassembly, &
Maintenance Instructions 7
Troubleshooting 8
Upgrades & Battery Replacement 9
Parts 10
Notes 11
F 13091 9/19
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2
HG-8 COLD CLIMATE FLUSHING SYSTEM
Installation Instructions
GENERAL
INSTALLATION
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
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)
Overview
The Hydro-Guard HG-8 Cold Climate
Unit, is the industry’s only Sub-
Surface Discharge, programmable
flushing apparatus. This Unit is
suitable for year-round use in 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 reference, training,
troubleshooting, and maintenance.
Hydro-Guard HG-8 Cold Climate
Flushing Unit
The Hydro-Guard HG-8 Unit is
housed in a Mueller Thermal-Coil
Box that is approximately 21
inches in diameter. The bury depth
will vary depending upon the depth
of the utility’s water lines. 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 coiled tubing that will
route water from the water utility’s
potable water distribution line to
the meter assembly, 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.).
The meter and flushing assembly
can be raised for maintenance and
repair and then lowered back down
into the box below the frost line.
A medium density foam insulation
pad, freeze protection system,
and composite lid help protect the
flushing and meter assembly from
freezing in the winter.
WARNING: Proper lifting,
loading / unloading tools and
techniques must be followed
when handling this device.
Damage to working components
can occur if dropped.
be installed inside of the HG-8’s
external cabinet. The catch pipe
shall be mounted at least 3" under
the discharge piping of the HG-8
(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.
!
1. Remove the Hydro-Guard Unit
from its packaging and inspect for
possible damage during shipping.
2. Turn off the service line feed.
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.
TYPICAL INSTALLATION
Cast Iron Vault Lid
Double Check Valve
1" Mueller Systems
Meter Sold Separately
8-Tablet Dechlorination
Supply
(By Others)
1" Male
Thread Ends
Discharge (By Others)
Grade
Ground
Programmer

3
HG-8 COLD CLIMATE FLUSHING SYSTEM
Installation Instructions & Programming Unit
INSTALLATION - (CONTINUED)
PROGRAMMING HYDRO-GUARD UNIT FOR OPERATION
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
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.
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.
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.
4. Slowly lower the Hydro-Guard HG-8
Cold 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.
6. Install the top approximately
1-1/2" below 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.
HG-8 (REQUIRES CONTROLLER)
Buetooth Programming
Instructions
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:
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)
11. 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.
12. The Hydro-Guard Automatic
Flushing Device may now
be programmed.
13. Once programming has been
set, slowly lower the flushing /
meter assembly into the lower
part of the protective, below-
grade, meter box. Insert the
foam pad insulator and install
cast iron meter lid.
WARNING: We do not
recommend the following:
1) Dumping fill material on top of
the pit; 2) Using machinery to
compact backfill.
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.
!
!
!
!

4
Programming Unit
HG-8 COLD CLIMATE FLUSHING SYSTEM
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.
8. Once the device is connected, it
will appear on the home screen
when you launch the Application.
Application Home Screen: Device Home Screen:
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.

5
Programming Unit
HG-8 COLD CLIMATE FLUSHING SYSTEM
Idle Mode – Waking Up
Normally the NODE isplay shows
time and day, day of week, and
battery life indicator. During a short
period of inactivity the display will
shut off to retain battery power
Pressing any key will wake up the
NODE to the Idle Mode.
Run Mode
When controller is operating a
program, items shown on display
will include station number (always
“1”), program letter (A, B, or C),
remaining runtime, and a blinking
Rotor icon.
Programming
The NODE has the capability to
hold 3 programs (A, B, C) and 4
start times per program. When
programming, flashing portion
of display can be changed by
pressing +or –keys. To change
something not flashing, press
LEFT or RIGHT ARROWS until
desired item is flashing.
HG-8 BUILT-IN: (INTEGRATED)
NODE Programming Instructions
Batteries
The NODE uses standard 9-volt
alkaline batteries to operate the
control valve and program the
controller. The controller can operate
with one or two batteries installed.
Under normal conditions, expected
life is 1 year for a single battery and
two years when using two.
Battery Installation
1. Unscrew rear body of the
NODE to gain access to
battery compartment.
2. Insert battery / batteries into
battery tray and connect the
battery connector to controller.
3. Make sure no water is inside
battery compartment.
4. Screw the NODE rear body back
onto front half.
NOTE: Make sure that seal marker
on rear half of the NODE lines up
with front half, ensuring a proper
seal is created. Also, The NODE has
non-volatile memory, which allows
battery replacement without losing
program information.
Setting Date / Time
1. Press RETURN / ENTER key until
CLOCK icon is displayed.
2. All 4 digits will be displayed
representing the year. Use +
or – keys to change year. Press
RIGHT ARROW key to proceed to
setting month.
3. All 4 digits will be displayed
with two digits on left flashing
representing the MONTH. Use +
or – key to change month. Press
RIGHT ARROW key to proceed to
setting DAY.
4. Only two digits on right will be
flashing, representing the DAY.
Press + or – key to change day.
Press RIGHT ARROW key to
proceed to changing TIME.
5. The AM / PM / 24 time setting
is shown flashing. Press +
or – key to change to AM, PM,
or 24-hour time. Press RIGHT
ARROW key to proceed to
setting the HOUR.
6. All 4 numbers are shown with
two numbers on the left flashing,
representing the HOUR. Press
+ or – key to change the hour.
Press RIGHT ARROW key to
proceed to setting MINUTES.
7. All 4 numbers are shown with
two numbers on right flashing,
representing MINUTES. Press
+ or – key to change minutes.
(Pressing RIGHT ARROW key will
return to YEAR setting at step
#2.)
8. Press RETURN / ENTER key to
proceed to next programming
function, or allow controller to
return to idle mode.

6
Programming Unit
HG-8 COLD CLIMATE FLUSHING SYSTEM
Setting Flushing Days
1. Press RETURN/ENTER key until
CALENDAR icon is displayed.
The program letter (A, B, or C)
will be displayed. Arrows point
at specific days of week in which
flushing
will occur.
2. Press LEFT or RIGHT ARROW to
scroll though days.
3. Press + key to activate that day
for program displayed, or – key to
cancel watering for that day. The
arrow will show on flushing days
for active program.
4. Press PRG key to set days
to flush for a different program,
if desired.
5. Press RETURN / ENTER key to
proceed to next programming
function, or allow controller to
return to idle mode.
Manual Flushing
Manual flushing allows user to test
the Hydro-Guard unit or a program
for a specified run time.
Make sure controller is in Idle Mode.
1. Press and hold RIGHT ARROW
until HAND icon is displayed. The
station number (always #1) will
be displayed in lower left side of
display along with RUN TIME.
2. Use the LEFT or RIGHT ARROW
to select #1 station if not
already displayed, and + or – key
to set manual flushing time.
3. To manually activate a program,
press PRG key. Program letter
(A, B, or C) will show on screen.
If a different program is needed,
press PRG key until desired
program is displayed.
4. To stop MANUAL FLUSHING
cycle press – key until time is
reduced to zero.
5. Press RETURN/ENTER key to
proceed to next programming
function, or allow controller to
return to idle mode.
Setting Flush Sequence
Start Times
1. Press RETURN / ENTER key until
CLOCK icon is displayed.
2. The START TIME will be
displayed flashing, along with
the program letter (A, B, or C) and
start time number (1, 2, 3, or 4)
in the upper left. Up to 4 different
start times can be set for each
program.
3. Use +or –key to change
START TIME for program
displayed. Each press of key will
change start time in 15-minute
increments.
4. Press RIGHT ARROW key to
add an additional START TIME
to program displayed. The start
time number is shown in upper
left corner of display.
5. Press PRG key to add START
TIME to a different program.
6. Press RETURN / ENTER key to
proceed to next programming
function, or allow controller to
return to idle mode.
Setting Flush Duration Times
1. Press RETURN / ENTER key until
HOURGLASS icon is displayed.
RUN TIME will be displayed
flashing. Also shown is program
letter (A, B, or C) and active
station number (always #1– all
other stations not used) on lower
left side of display.
2. Press +or –key to change
station RUN TIME from 1 minute
to 6 hours.
3. Press PRG key to add a
RUN TIME to another program.
4. Press RETURN/ENTER key to
proceed to next programming
function, or allow controller to
return to idle mode.
NOTE:
– Pressing + or – key when running
in MANUAL FLUSH mode will modify
FLUSH TIME for that station.
– Pressing the button when a
station is running in manual
watering will stop irrigation on the
current station and advance to the
next station.
– Pressing the button when a
station is running in manual
watering will stop the irrigation on
the current station and revert to
the previous station.
Turn System Off
To turn off controller, press
RETURN/ENTER key button
until icon resembling water
spray and OFF is displayed on
screen. To return controller to
auto programming mode, press
RETURN/ENTER key. The controller
will immediately return to auto
programming mode and will display
time and battery life indicator.
NODE Quick Check
This circuit diagnostic procedure
can quickly identify “shorts”
commonly caused by faulty solenoids
or when bare common wire touches
a bare station control wire. To initiate
NODE Quick Check procedure:
1. From Idle Mode, press and
hold +, –, LEFT ARROW, and
RIGHT ARROW keys.
2. Display will show all segments.
Release keys.
3. Press +key to initiate
NODE Quick Check test.
4. Controller will then activate
flushing unit for 1 second to
verify operation.

7
Disassembly / Reassembly Instructions
HG-8 COLD 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
Cold 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 or
cast iron lid of HG-8 protective
ground sleeve.
3. Remove foam insulation pad.
4. Using the lifting holes and/or
lifting strap in the steel platform,
raise the flushing system meter
assembly to top of meter box
and lock into place.
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 to top of
PVC in-ground protective housing
and lock into place.
2. Unscrew solenoid from valve – be
careful to not drop the
solenoid plunger and spring into
in-ground housing.
3. Using the TBOS-II handheld,
connect the infrared connector of
the handheld to the antenna on
the controller interface mounted
inside of the device. Using
the programming keys of the
handheld run a 2 minute manual
flush sequence.
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 / metering assembly
below grade by slowly lowering the
steel mounting plate to the lower
part of the in-ground protective
housing (DO NOT apply excessive
force to assembly).
3. Turn water supply to the unit
on. Using the TBOS-II handheld
controller, run a two minute
manual flushing procedure to
confirm all components are
operational.
4. Return insulation pad and cast
iron lid to their proper location.
!

8
Troubleshooting
HG-8 COLD CLIMATE FLUSHING SYSTEM
TROUBLESHOOTING THE PROGRAMMER
TROUBLESHOOTING THE UNIT
• Check to make sure the
flow control knob is open
on the valve OR Check the
pipes for obstructions OR
Check the valve.
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
around the diaphragm.
Try this Correction
• Run a manual flush for
1 minute.
• Change batteries.
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.
Try this Correction
• Check if curb stop is open.
• Change batteries.
• Check connections for
corrosion, breaks, or lack
of connection.
• Run a manual flush and
confirm the solenoid
plunger is kicking out and
pulling back in by listening
for a click.
• 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

9
Upgrades & Battery Replacement
HG-8 COLD CLIMATE FLUSHING SYSTEM
HYDRO-GUARD FEATURES, UPGRADES AND SAMPLE COLLECTION
BATTERY REPLACEMENT
Dechlorination
The Hydro-Guard HG-8 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.
HG-8 Built-In (NODE)
Programming:
Unscrew cap from bottom of NODE
programmer housing. Insert two
9-volt alkaline batteries. Tighten cap
completely to ensure a water tight fit.
4. Place the battery back into
the watertight integrated T-2
programming interface making
certain to tighten the screw-on lid
until snug.
The following is a brief overview and
introduction to our options.
Integrated Sample Station
The HG-8 Cold 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-S116 Portable
Sample Valve will be required.
(Recommendation: one HG-S116
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. Using the lifting holes and/or
lifting strap in the steel mounting
platform, raise the internals of
the HG-8 to the surface.
5. Return the internals of the HG-8 to
its proper location.
6. Return the insulation pad and
cast iron lid to their
proper locations.

10
Parts
HG-8 COLD CLIMATE FLUSHING SYSTEM
ID PART # DESCRIPTION
1546787 Composite or Cast Iron Vault Lid
2 546799 HG-8 Plate Rest
3546785 2" Foam Insulation Pad
4790015 21" Ø Below-Grade Vault
5HG-A102L 9-Volt Lithium Battery
6546779 1" Valve & Meter
Replacement Assembly
7 700014 Reinforcing Ring
8 546025 1" Coiled Tubing Assembly
9 HG-A119 320 Inline Dechlorination Assembly
10 HG-FP100 Thermal Control Valve
11 546138-100 1" Backflow Double Check Valve
12 014215 330N 1" Meter Coupling
13 024265 1 330N 1" Ball Angle Meter Valve
14 014210 1 330N 1" Meter Coupling
15 700507 Flow U-Bar w/ Hole for FP
16 HG-FP100 Thermal Control Valve
17 5461219 Coated Steel Mounting Platform
18 700507 U-Bar
19 546596 Latching Solenoid
20 HG-FP108C Molded Freeze Adapter / Gasket
21 HG-11010 1" Flow Control Valve
22 HG-V139 3/8" Poly Tubing
REPLACEMENT PARTS
1
2
3
4
5
6
7
8
15
16
21
20
19
22
18
17
9
10
14
13
11
12

11
Notes
HG-8 COLD CLIMATE FLUSHING SYSTEM

12
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