Muller Hudro-guard 100 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

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).

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

procedures 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:

1. 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.

100 Series

Cold Climate

Automatic

Flushing System

Installation Instructions 2

Programming Unit 3

Assembly, Disassembly &

Maintenance Instructions 4

Troubleshooting 5

Parts 6

F 12774 5/21

100 SERIES COLD CLIMATE FLUSHING SYSTEM

Installation Instructions

GENERAL

INSTALLATION

performance. Please read and

retain this manual.

Site Evaluation

Each Hydro-Guard®Flushing

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

Overview

The Hydro-Guard®100 Series

Cold Climate Flushing System

Automatic Flushing System, the

industry's premium patented,

programmable flushing apparatus,

is suitable for year-round use in

moderate to severe cold climates.

This Automatic Flushing System

has been designed, engineered,

and manufactured to provide

outstanding dependability and

Hydro-Guard 100 Series Cold

Climate Flushing System

Atmospherically Discharged

Flushing Unit

1. Remove the Hydro-Guard®Unit

from Its packaging and inspect for

possible damage during shipping.

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.

3. Slowly lower the Hydro-Guard®

Unit into place, pressing it firmly

into the noncompacted 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).

4. Connect the utility's water system

to the Hydro-Guard®Unit by means

of the 2" threaded connection.

5. Backfill the hole around the Unit

with clean fill and/or #57 stone.

Backfilling should be accomplished

in 6" compacted lifts. Check that

the Unit is level.

flow away from the Hydro-Guard®

Flushing Unit or to be absorbed by

the surrounding soil.

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.

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.

TYPICAL INSTALLATION

Round cut, ½" thick,

marine grade splash plate

guards against erosion

and provides added

stability for the 100

Series Cold Climate

Medium Density Polyethylene

enclosure is UV protected and

offers impact resistance; the

upper section of the enclosure

is removable and lockable

Stainless security

screws and unique lock

protect the 100 Series

Cold Climate from

unauthorized access

Nylon reinforced composite

control valve with adjustable

control, single piece EPDM

diaphragm and straight

through pass for debris

build-up reduction.

Superior grade stainless steel

diffuser screen diffuses the

discharging water and guards

against nesting rodents, frogs

and snakes

Patented Camlock

release system allows

for easy disassembly

and reassembly –

maintenance in minutes

OEM-installed

sampling port and

dechlorination

systems are standard

equipment on the 100

Series Cold Climate

The 15-inch diameter below

grade protective 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 100

Series Cold Climate.

100 SERIES COLD CLIMATE FLUSHING SYSTEM

Programming Unit

PROGRAMMING HYDRO-GUARD UNIT FOR OPERATION

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.

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:

To add

another

controller, tap

the plus sign

in the upper

right hand

corner of the

home screen.

Device 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.

100 Series Cold Climate

(Requires Bluetooth 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.

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

Assembly, Disassembly & Maintenance Instructions

100 SERIES COLD CLIMATE FLUSHING SYSTEM

100 SERIES COLD CLIMATE DISASSEMBLY AND REASSEMBLY INSTRUCTIONS

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

Erosion Controlling 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.

Reassembly

1. Return internal assembly to

proper location and lock the Cam-

Lock handles in place on the

female side of the Cam-Lock.

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

polytube, and place it over pipe

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-A 104 Security Wrench

to tighten them securely.

6. Lower Dechlorination Chamber

Bracket to original position and

retighten two nuts securely.

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.

100 Series Cold Climate

Battery Replacement

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 Bluetooth or NODE (Built-in)

Controller to reset all programs and

assure flushing sequence is correct

prior to returning the 100 Series

Cold Climate Unit to service.

8. Reinstall Exterior Housing Cover

and restore water supply to unit.

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

7. Reinstall Knob onto Sampling

Valve Push Rod.

8. Check battery life of Battery

in Programming Interface or

onboard 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.

Reloading Dechlorination Chambers

1. Follow Instructions "100 Series

Cold Climate Machine Disassembly,

steps 1 - 3.

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 #9 above to

reinstall Exterior Housing Cover, and

restore water supply to unit.

TOOLS NEEDED: HG-A 104 Security Wrench, HG-A2023 Security Tool, Philips screwdriver, at-head screwdriver

Troubleshooting

100 SERIES COLD CLIMATE FLUSHING SYSTEM

TROUBLESHOOTING THE CONTROLLER

TROUBLESHOOTING THE UNIT

The Hydro-Guard® Unit

will not shut off:

Possible Causes

• The solenoid is stuck in the

open position or debris is

interfering with operation of

plunger.

• Batteries weak or dead.

• Connection loss from battery

box to solenoid.

• The solenoid is loose or there is

debris In the plunger.

• There is a hole in or debris

around the diaphragm or in the

valve screen.

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 to make sure the flow

control knob is open on the

valve OR check the pipes for

obstructions OR check the valve.

Try this Correction

• Run a manual flush for 1 minute.

• 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 CA CAUSE USE C SOLUTION

Controller does not ush as desired Water at main water supply is shut off Check main supply valve

Battery dead Replace battery

Controller set to OFF Set controller to desired program

Controller improperly programmed Check program and clock settings

Blank display Battery dead Replace battery

Water does not turn off Overlapping programming Review all programming and edit any

program that is in conict 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 nger 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)

Parts

100 SERIES COLD CLIMATE FLUSHING SYSTEM

PROGRAMMING HYDRO-GUARD UNIT FOR OPERATION

REPLACEMENT PARTS

ID PART # DESCRIPTION

1546284 UV Protective Housing

2FC100-BL Bluetooth Controller Assembly

3546521 Sample Valve Assembly

4546329 Riser Assembly

5546519 Dechlorination System

6HG-S316 Stainless Steel Housing Bracket

7545729 Centering Star

8HG-S126 Insulation Star Sub-Assembly

9HG-S128 Freeze Protection System Sub-Assembly

10 545729 Centering Star

11 545738 Splash Pad

12 HG-13105 Latching Rods ¼" x 26"

13 HG-S124 Latching Solenoid Sub-Assembly

14 HG-S325 Control Valve Sub-Assembly

15 546330 Bottom Plate Sub-Assembly

Notes

100 SERIES COLD CLIMATE FLUSHING SYSTEM

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).

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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