Waterous 200-B Operating and safety instructions

Installation / Maintenance Guide
Applies to Waterous Model
200-B Rev-
BELT-Driven Compressor Kit
FOR INSTALLATION CENTER USAGE ONLY
Waterous, Arizona Operations
7612 North 74th Ave.
Glendale, Arizona 85303
623-979-3398
Fax: [phone]
www.waterousco.com

Waterous 200-B Belt-Driven Installation Guide Rev-
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Warnings, Cautions, and Notes
Warning
A warning alerts you to a procedure, practice or condition that may result in death or
long term injury to personnel or destruction of equipment.
Caution.
A caution alerts you to a procedure or condition that may result in serious
damage to equipment or its failure to operate as expected
Note: A note points out important information. Failure to read the note will not
result in physical harm to personnel or equipment. It may waste time
and money.
Revision History
Revision
Date Issued
Comments
---
08/16/06
Original Release
Disclaimer: These instructions are guidelines only and in no way meant to be definitive. During installation, standard
safety precautions and equipment should be used where appropriate. Because the tools used and the skill/experience of
the installer can vary widely, it is impossible to anticipate all conditions under which this installation is made, or to provide
cautions for all possible hazards. Proper installation is the responsibility of the purchaser. All bolts, setscrews, and belts
must be checked prior to start-up AND after the initial operation. Damages due to poor installation are the responsibility of
the installer.

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Table of Contents
SECTION 1. INSTALLATION OVERVIEW................................................................................. 5
A. Installing Waterous Components ....................................................................................... 6
SECTION 2. AIR COMPRESSOR INSTALLATION................................................................... 7
A. 200-B Compressor ............................................................................................................. 7
B. Air Inlet and Filter ............................................................................................................... 9
SECTION 3. AIR-OIL RESERVOIR (SUMP) INSTALLATION................................................. 10
A. Vertical Sump ................................................................................................................... 10
B. T-Sump............................................................................................................................. 11
C. Oil Fill and Sight Glass ..................................................................................................... 12
D. T-Sump Drain ................................................................................................................... 13
SECTION 4. OIL TEMPERATURE GAUGE (ALL SUMPS)..................................................... 13
SECTION 5. SEPARATOR/FILTER INSTALLATION.............................................................. 14
SECTION 6. HEAT EXCHANGER INSTALLATION ................................................................ 15
A. Connecting the Cooler Water Lines and Wye-Strainer .................................................... 16
B. Wye Strainer for Cooler.................................................................................................... 17
SECTION 7. HYDRAULIC FILTER INSTALLATION................................................................ 18
SECTION 8. AUTO-SYNC CONTROL SYSTEM INSTALLATION.......................................... 19
A. Manual Valves.................................................................................................................. 19
B. Electric Valves (Solenoids)............................................................................................... 20
SECTION 9. BALANCE VALVE INSTALLATION .................................................................... 21
SECTION 10. INITIAL POWER-UP....................................................................................... 22
A. Post-Installation, Pre-Power up Safety Check ................................................................. 22
B. Initial Compressor System Power-up............................................................................... 22
SECTION 11. ADJUSTING THE AUTO-SYNC AIR BALANCING SYSTEM ........................ 23
A. Auto-Sync......................................................................................................................... 23
B. FIXED Mode Adjustment.................................................................................................. 24
C. AUTO Mode Adjustment................................................................................................... 25
SECTION 12. SUGGESTED THIRD-PARTY COMPONENTS ............................................. 27
A. Suggested components for CAFS discharges: ................................................................ 27
B. Suggested Air Hose.......................................................................................................... 28
C. Discharge Fittings............................................................................................................. 28
D. Suggested for 1.5” and 2” discharges: ............................................................................. 29
E. Suggested for 2-1/2” discharges: ..................................................................................... 29
F. Suggested fittings for auxiliary air outlet:.......................................................................... 30
G. Air distribution manifold: ................................................................................................... 30
SECTION 13. AUTO-SYNC SYSTEM................................................................................... 30
SECTION 14. TROUBLESHOOTING.................................................................................... 31
A. CAFS................................................................................................................................ 31
B. PUMP ............................................................................................................................... 35

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Figure 1 200-B Compressor........................................................................................................... 7
Figure 2 200-B Compressor, rear view........................................................................................... 8
Figure 3 200-B Bottom mounting bolt pattern (center to center).................................................... 8
Figure 4 Universal Mounting Bracket ............................................................................................. 9
Figure 5 Adjustable Mounting Head............................................................................................... 9
Figure 6 Vertical sump.................................................................................................................. 10
Figure 7 200-B T-Sump, Side View.............................................................................................. 11
Figure 8 Temperature sender on Sump ....................................................................................... 13
Figure 9 Separator/filter side view with fittings............................................................................. 14
Figure 10 Separator/filter and bracket detail ................................................................................ 14
Figure 11 Oil Inlet/Outlet Ports..................................................................................................... 15
Figure 12 Water Inlet/Outlet Ports and Drain ............................................................................... 15
Figure 13 Freeze damage to undrained cooler, also showing the small diameter of the water
tubes.............................................................................................................................. 15
Figure 14 Adjustable Mounting Brackets...................................................................................... 16
Figure 15 Cooler mounted on the side of a pump compartment, with the cooler body sloping
toward the drain for better drainage.............................................................................. 16
Figure 16 Wye Strainer.................................................................................................................. 17
Figure 17 Wye-strainer installed, with cleanout valve.................................................................. 17
Figure 18 Clean Strainer .............................................................................................................. 17
Figure 19 Dirty Strainer ................................................................................................................ 17
Figure 20 Bracket and filter .......................................................................................................... 18
Figure 21 Hydraulic Filter, top, showing flow direction arrows..................................................... 18
Figure 22 Auto-Sync Manual Valve Assembly............................................................................. 19
Figure 23 Auto-Sync Control Switches and Label....................................................................... 19
Figure 24 Typical Air Pressure Gauge ........................................................................................ 19
Figure 25 Auto-Sync Control Switch and Label (electric)............................................................ 20
Figure 26 Auto-Sync valve assembly, front (electric).................................................................. 20
Figure 27 Piloted Balance Valve inlets and outputs, with push-on hoses.................................... 21
Figure 28 Manual Valve Control................................................................................................... 23
Figure 29 Electric Valve Control................................................................................................... 23
Figure 30 Compressor adjustment points .................................................................................... 24
Figure 31 Piloted Balance Trim Valve (PBTV)............................................................................. 24
Figure 32 Typical CAFS Discharge.............................................................................................. 27
Figure 33 Basic CAFS System..................................................................................................... 39
Figure 34 200-B with “T” Sump .................................................................................................... 40
Figure 35 200-B with Vertical Sump............................................................................................. 41
Figure 36 Compressor Dimensions.............................................................................................. 42
Figure 37 "T" Sump Dimensions .................................................................................................. 43
Figure 38 10" Vertical Reservoir................................................................................................... 44
Figure 39 Oil Cooler ..................................................................................................................... 45
Figure 40 200-B Oil and Separator............................................................................................... 46
Figure 41 Separator Bracket ........................................................................................................ 47
Figure 42 Hydraulic Schematic with "T" Sump............................................................................. 48
Figure 43 Hydraulic Schematic with Vertical Sump...................................................................... 49
Figure 44 Electrical Schematic for Auto-sync............................................................................... 50
Figure 45 Air Schematic, Electric Auto-sync, 90° Inlet................................................................. 51
Figure 46 Air Schematic, Manual Auto-sync, Vertical Inlet .......................................................... 52
Figure 47 Air Schematic, Manual Auto-sync, 90° Inlet................................................................. 53
Figure 48 Panel Cutouts, Electrical & Manual Controls ............................................................... 54

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SECTION 1. INSTALLATION OVERVIEW
Notes: The instructions are for a typical system. A custom order system will have a
similar installation procedure.
The illustrations shown in this manual may differ slightly from the parts that were shipped.
The primary use of the compressor kits is to provide compressed air for Compressed Air
Foam Systems (CAFS) in fire-fighting vehicles. Water to cool the compressor is supplied
by the vehicle's pump, from its tank or an exterior source. If the kit is not installed in a
fire-fighting vehicle, the compressor requires alternate cooling, such as an air-oil cooler.
The compressor kits do not include:
Drive Components
Foam proportioner, foam tank, foam distribution manifold for CAFS
Air, water and hydraulic hoses and hose fittings
Compressor (air end) mounting bracket
Air inlet piping
Air and water check valves
Air discharge valves
Air manifold
Master air pressure gauge
New installation tasks include:
Installing the foam proportioner (follow the manufacturer's instructions)
Installing the compressor and connecting it to the Drive Components
Installing the rest of the hydraulic system (sump, filters and cooler)
Installing gauges, valves, and the Auto-Sync controls
Running water, air and hydraulic tubing for control systems, cooling, and
compressed air delivery.
Filling and testing the hydraulic system
Calibrating the Auto-Sync system

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Retrofitting into existing apparatus also includes:
Modifying the water distribution system to install compressed air inputs, foam
distribution manifold, check valves, the compressor cooling loop, and the balance
valve.
Installing additional discharges (optional)
A. Installing Waterous Components
Refer to the Basic CAFS, Hydraulic, and Auto-Sync schematics in this manual to see how
the Waterous components connect to the vehicle's foam and water distribution systems.
Within the guidelines given here, components can be installed wherever there is room for
them to be securely mounted. See the dimensional drawings in the rear.
Warning:
Do not damage the vehicle chassis (also called frame or undercarriage) during
installation. Check with the vehicle manufacturer to make sure the planned welds
and bolts are in acceptable areas.
Components must be bolted to brackets welded to the pump compartment frame,
or bolted directly to the pump compartment frame.
Allow enough clearance for routine maintenance, including clearance for
checking oil, adding oil, adjusting pressure, changing filters, cleaning screens or
opening drain valves.
The sump (oil/air reservoir) can be mounted at the same level as the
compressor, or below it. If the sump must be mounted above the compressor
(12 inches maximum), contact Waterous for the correct check valve to prevent
compressor flooding.
The sump must be horizontal, level, and in the proper orientation. Any extension
to the sight glass must be straight and level.
The oil sight glass must be visible after all the components are installed so oil
level can be monitored easily.
The heat exchanger must be installed horizontally, with the drain at the lowest
point.
To prevent damage to hydraulic and air lines, or accidentally disconnecting them,
run them along the support beams of the pump compartment whenever possible,
bundled with cable ties or other fasteners.
Wires, hoses, or tubing that passes through metal, such as a compartment panel,
must have a protective bushing or shield around the edge of the hole to protect
against abrasion.
To make troubleshooting easier, use colored air hoses as supplied, and shown
on the air schematic.
Labeling the lines is strongly recommended.

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SECTION 2. AIR COMPRESSOR INSTALLATION
All fasteners should be checked by the installer prior to operating the unit.
Caution:
The air compressor cannot be installed on its side. It must remain upright,
with the air intake on the top.
A. 200-B Compressor
Air Inlet Trim Valve
Fixed / Manual
Pressure Regulator
Air Inlet
Input Shaft
Figure 1 200-B Compressor

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Oil/Air
Discharge
to sump
Outlet
flange and
gasket
Oil return from
Separator Filter
Oil inject from
Cooler
Figure 2 200-B Compressor, rear view
Make a bracket for mounting the air compressor or purchase the universal mounting
bracket kit from Waterous. The correct metric mounting bolts (16 mm) are provided with
the compressor kit.
Bolted to a bracket under the compressor body.
The bracket must fit between the discharge plate and the oil inject fitting. Typically the
bracket will be made of square tubing welded between two pump compartment framing
tubes, and have a steel mounting plate with the proper hole pattern welded to the top of
the support.
Oil Inject
Compressor Mounting Holes
M 16 x 1.5 x 30mm
Discharge
Discharge
Mounting
Holes (4)
3.78” (96mm)
3.94”(100mm)
Figure 3 200-B Bottom mounting bolt pattern (center to center)

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A "universal mounting bracket" for the 200-B is included from Waterous. The bracket
arm is bolted in place, using the vertical extension if needed, and the adjustable mounting
head moved left or right to position the compressor. After the position is determined,
weld the mounting head to the bracket arm to secure the compressor.
Figure 4 Universal Mounting Bracket
Figure 5 Adjustable Mounting Head
B. Air Inlet and Filter
The air inlet on the air compressor can be turned in 90° increments because the bolt
pattern is symmetrical. This simplifies installation of the air filter. If you turn the inlet,
you will need longer tubing. Either acquire colored tubing locally or contact Waterous
for the correct lengths and colors.
To change the rotation of the air inlet, disconnect the tubing, unbolt the inlet, rotate
the inlet, and install new tubing.
Mount the air filter, considering the following factors:
Air intake area must be unobstructed.
Air intake tubing should be as short and straight as possible.
Maintenance clearance must be adequate for removing and replacing the
filter.
The filter should be in an area that is unlikely to get wet.
The air inlet tubing (not included) from the filter to the air inlet is usually made of thin-
wall metal tubing and rubber elbows. Plumb it as though it were an engine air inlet.
Do not use flexible exhaust tubing or any material that water or dirt can easily
penetrate.

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SECTION 3. AIR-OIL RESERVOIR (SUMP)
INSTALLATION
Note: Waterous will not be responsible for systems where the sump and sight glass are
installed such that the oil level cannot be checked or does not display the correct
oil level due to improper installation.
The sump works best when it is installed so that the sight glass opening is below the
discharge outlet of the air compressor, although mounting the sump at the same level as
the compressor is acceptable. In some cases, finding room for the sump can be difficult.
It is acceptable to mount the oil sump up to 12 inches higher than the air compressor;
however this requires the installation of a check valve to prevent oil from flooding the
compressor. The check valve may be ordered from Waterous when ordering the system.
The 200-B has two sump styles, the usual vertical sump and the optional "T-shaped"
sump.
A. Vertical Sump
Some models of this sump may have alternate connection for temperature sender at
plug by oil drain.
INLET FROM
COMPRESSOR
OIL FILL
OIL LEVEL
SIGHT GLASS
OIL RETURN
TO TEMPERATURE
SENDER
OIL DRAIN
OUT TO
SEPARATOR FILTER
PRESSURE
RELIEF VALVE
MOUNTING
BRACKET
LEFT SIDE
VIEW
Figure 6 Vertical sump
Vertical sump, reverse view

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B. T-Sump
From
Compressor Sight Glass
and Fill
To Separator Filter
To Hydraulic Filter
and Drain
Safety
Pressure
Relief
Sender for
Temperature Meter
Figure 7 200-B T-Sump, Side View
The sump has mounting holes in the legs. Bolt the sump to the pump
compartment frame.
Make sure there is adequate clearance for the fittings and lines under the sump.
The T-sump has two possible outlets for the line that goes to the separator filter.
A plug is provided to close the unused outlet.

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C. Oil Fill and Sight Glass
The oil fill and sight glass on the T-sump have 3 possible positions. They may share
the same inlet if installed in a wye fitting as shown below, or be installed in separate
inlets. Locate these fittings for ease of checking oil level and adding oil to the sump.
Use the supplied plugs to close the unused inlets.
If the oil sight glass needs to be extended for visibility, use rigid pipe to ensure that
the level displayed is as accurate as possible. The sight glass/oil fill extension must
be straight and level.
Oil fill and sight glass in a Wye fitting
Ideal installation, with sight glass and oil fill
easy to access
90° Elbow on a sight glass for better
visibility
Two elbows on an oil fill cap for accessibility

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D. T-Sump Drain
The drain and the output to the hydraulic filter share an outlet port.
To Hydraulic
Filter
Drain
SECTION 4. OIL TEMPERATURE GAUGE (ALL SUMPS)
Mount the gauge on the pump operator's control panel where it will be easy to monitor.
The gauge connects to the larger of the
two prongs on the sender.
The smaller prong, which is labeled "WK",
may be used to activate an oil temperature
warning light or alarm (not provided).
Waterous recommends installing an over-
temperature device.
This prong is one side of a temperature
sensitive switch that will close at 250°F.
The other side is grounded through the
metal of the sump.
The prong can be connected to the
negative side of an audible alarm or
warning light.
Follow the installation instructions in the
temperature gauge box to connect the
sender to the gauge and the optional
warning light.
Figure 8 Temperature sender
on Sump

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SECTION 5. SEPARATOR/FILTER INSTALLATION
The separator filter can be installed anywhere there is room to securely mount it and run
the hydraulic and air lines.
Install it vertically, with the housing up, the filter element down.
Make sure there is room to remove and replace the filter element.
From
Sump
To Balance Valve and
Fixed/Manual Regulator
Oil Scavenger to
Compressor
To Air
Manifold
Figure 9 Separator/filter side view with fittings
Oil Scavenger
to Compressor
From
Sump
Figure 10 Separator/filter and bracket detail

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SECTION 6. HEAT EXCHANGER INSTALLATION
Caution:
Do not install a shutoff valve in the heat exchanger water supply. This will
result in system overheat and failure, and void the manufacturer’s warranty.
The oil returning to the compressor is cooled by passing it through a water-cooled heat
exchanger, usually called the cooler.
Oil
Inlet
Oil
Outlet
Drain
Water Inlet
and Outlet
Drain
Water
Inlet
Water
Outlet
Figure 11 Oil Inlet/Outlet Ports
Figure 12 Water Inlet/Outlet Ports and
Drain
The oil inlet and outlet may be reversed if it makes installation easier.
The water inlet and outlet may be reversed if it makes installation easier.
Install the cooler so that it can be drained to prevent freeze damage.
Figure 13 Freeze damage to undrained cooler,
also showing the small diameter of the water tubes
The cooler must be installed horizontally, with the drain at the lowest point, and with a
slight slope toward the water drain end.
The drain hose should be 0.5” I.D. minimum to provide proper drainage.

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The outlet of the drain hose must be lower than the cooler's drain outlet and the drain
hose should be a continuous downward run (no goosenecks) to allow proper
drainage.
To mount the cooler on the side of a compartment, unbolt the brackets from the ends
and reattach them so the cooler can be installed with the drain at the lowest point.
Bracket
Figure 14 Adjustable Mounting Brackets
Figure 15 Cooler mounted on the side of a
pump compartment, with the cooler body
sloping toward the drain for better drainage
A. Connecting the Cooler Water Lines and Wye-Strainer
The cooler water is supplied by diverting water through a fitting (OEM supplied) from
the discharge side of the fire pump (see the Hydraulic Schematic). The cooling water
supply hose should be 1/2” I.D. for the 200-B to supply the proper flow for cooling the
system. The cooler discharge water may be routed to the booster tank fill tower or
returned to the inlet side of the pump, as per the end user's preference.
Normally, coolant water is returned to the booster tank and a check valve is installed
in-line to prevent backflow from the tank through the cooler. During drafting and
hydrant-supplied operations, the booster tank may overflow because of the cooler
water return. If this is objectionable, route the return line to the inlet side of the pump.
In this case, it is not necessary to install an in-line check valve, but it will be
necessary for the pump operator to open the tank fill valve during operation to
prevent overheating the fire pump.

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B. Wye Strainer for Cooler
A wye-strainer is provided to strain water before it enters the cooler's water inlet. The
wye strainer requires regular inspection, and should be in an easily accessible
location for inspection, removal, and cleaning.
Caution:
Waterous is not responsible for damage due to plugged strainers. If
the customer's water system contains excessive debris, or the vehicle
relies on drafting for its water supply, it may be necessary to install a
larger strainer and/or a clean-out valve on the wye-strainer.
Without good water flow through the heat exchanger, the compressor
will overheat. Compressor performance will be inadequate, and it may
fail completely.
Omitting the Wye-strainer or removing the screen from the Wye does
not improve water flow. It will allow debris into the cooler, which can
clog the tiny heat exchanger tubes and restrict water flow.
Figure 16 Wye Strainer
Figure 17 Wye-strainer installed, with
cleanout valve.
Figure 18 Clean Strainer
Figure 19 Dirty Strainer

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SECTION 7. HYDRAULIC FILTER INSTALLATION
Caution:
This is a one-way filter. Oil must flow in the direction indicated by the arrows
on the top of the filter.
Flow
Figure 20 Bracket and filter
Figure 21 Hydraulic Filter, top, showing flow
direction arrows
Install the hydraulic filter on the bracket provided, as shown in the hydraulic schematic, in
any available location near the compressor.
Install with the housing up, the filter element down.
Make sure there is enough room so the filter can be removed and replaced.
Make sure the direction of oil flow is correct.
NOTE: Waterous has phased out in-line thermostats from the hydraulic circuit.

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SECTION 8. AUTO-SYNC CONTROL SYSTEM
INSTALLATION
The Auto-Sync control system will have manual or (optional) electric control valves.
A. Manual Valves
FIXED/AUTO Side RUN/UNLOAD Side
Figure 22 Auto-Sync Manual Valve Assembly
Figure 23 Auto-Sync Control Switches
and Label
Figure 24 Typical Air Pressure
Gauge
Install the control switch assembly and the master air pressure gauge (not included) on
the pump control panel.
1. Turn the control knobs to FIXED and RUN.
2. Loosen the setscrews and remove the knobs and nuts from the front of the
assembly.
3. Remove the label plate.
4. Use the label as a template for making the holes for the control valves and the
mounting bolts, or use the dimensional drawing provided.
5. From the rear, insert the valve stems through the mounting holes.

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6. Attach the label to the pump control panel.
7. Replace the nuts and knobs on the front of the assembly, making sure to align
the knob indicators to FIXED and RUN.
8. Make sure the knobs do not bottom out on the valve bodies. This will prevent the
system from working properly.
9. Tighten the setscrews.
B. Electric Valves (Solenoids)
The electric valve assembly comes on a mounting bracket with the connecting wires and
connector already installed.
Figure 25 Auto-Sync Control Switch
and Label (electric)
Figure 26 Auto-Sync valve assembly,
front (electric)
1. Install the valves in a convenient location, close enough to the pump operators
control panel to run the control wires.
2. Install the valve control switch and label on the pump operator's control panel.
3. Run the control wire from the valves to the switch and plug the connectors together.
4. Connect the remaining wire to a +12V supply.
5. Secure the control signal wire to the compartment frame.
Note: If there is excess wire, do not coil it. Coils of wire act as antennas, either
receiving or radiating stray EMF signals and interfere with this or other
equipment. Bundle the wire harness back on itself, and secure it in a bundle with
the folded wires parallel to each other.