Waterous 500-100-P User manual

12/22/2011
Operation Guide
Applies to Waterous Model
500-100-P
500-120-P
Rev 1
Unit Serial Number ______________________
Waterous Arizona Operations
7612 North 74th Ave.
Glendale, Arizona 85303
623-979-3398
Fax: [phone]
www.waterousco.com

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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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 may not result in
physical harm to personnel or equipment. It may waste time and money.
Revision History
Revision
Date Issued
Comments
---
11/2005
Original Release
1
12/22/11
Reformat, new logo, updated pics, more
tables
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.

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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Table of Contents
SECTION 1. OPERATING INSTRUCTIONS.........................................................................................4
A. Multiple Uses.....................................................................................................................................4
B. For Electric Auto-Sync ......................................................................................................................4
I. Water Pumping Operations...........................................................................................................5
II. Foam Solution Operations ............................................................................................................5
III. Compressed Air Foam Operations................................................................................................5
IV. Compressed Air Only Operation ...................................................................................................6
C. Shut-Down Procedure.......................................................................................................................7
SECTION 2. COMPRESSOR ................................................................................................................8
A. How It Works.....................................................................................................................................8
SECTION 3. SYSTEM SERVICE AND MAINTENANCE.......................................................................9
A. Maintenance Schedule....................................................................................................................10
B. Maintenance Items..........................................................................................................................10
C. Wye Strainer for Cooler...................................................................................................................11
SECTION 4. CAFS NOZZLE / FLOW RATE / HOSE COMBINATIONS .............................................12
A. Nozzles............................................................................................................................................12
B. Foam Concentrate Ratios ...............................................................................................................12
C. Hose................................................................................................................................................12
SECTION 5. SUGGESTED GUIDELINES FOR THE PRODUCTION OF MID-RANGE
COMPRESSED AIR FOAM........................................................................................................................13
A. 1” (25 mm) Hose Diameter Jacketed..............................................................................................13
B. 1-1/2” (38 mm) Hose Diameter .......................................................................................................13
C. 1-3/4” (44 mm) Hose Diameter .......................................................................................................14
D. Master Stream.................................................................................................................................15
SECTION 6. TROUBLESHOOTING....................................................................................................16
A. CAFS...............................................................................................................................................16
B. Pump...............................................................................................................................................20
SECTION 7. CONDITIONAL 5-YEAR WARRANTY POLICY..............................................................30
Figure(s)
Figure 1 Electric Auto-sync panel ................................................................................................................4
Figure 2 Wye Strainer .................................................................................................................................11
Figure 3 Wye-strainer installed, with cleanout valve..................................................................................11
Figure 4 Clean Strainer..............................................................................................................................11
Figure 5 Dirty Strainer................................................................................................................................11
Figure 6 Basic CAFS Schematic................................................................................................................24
Figure 7 500-100-P Dimensions ...............................................................................................................25
Figure 8 Hydraulic Schematic....................................................................................................................26
Figure 9 Air Schematic, Electric Auto-sync, 90° inlet.................................................................................27
Figure 10 Electric Schematic, Auto-sync...................................................................................................28
Figure 11 Compressor Installation Angles.................................................................................................29

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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SECTION 1. OPERATING INSTRUCTIONS
Check the following fluid levels daily or prior to operating system:
Compressor system oil (Oil level should be visible within the sight glass on the sump and
should be checked daily or before or after use.)
Foam concentrate
Onboard water supply
A. Multiple Uses
The Waterous compressed air foam unit can be operated in several pumping modes: water
only, foam solution without compressed air, compressed air foam, and compressed air only
for support operations such as operating air tools, filling rescue air bags, etc. It is possible to
pump foam solution from one discharge while pumping compressed air foam from another, or
varying foam consistencies (expansion ratios) from different discharges simultaneously.
NOTE: Monitor compressor instruments during any and all operations.
WARNING:
Prior to starting the engine, the Auto Sync controls should be in the UNLOAD position,
which allows the air compressor to “free wheel” without pumping air.
B. For Electric Auto-Sync
Figure 1 Electric Auto-sync panel

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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I. Water Pumping Operations
All unit operations begin with pumping water. These steps must be followed for
operations involving pumping water, foam solution, compressed air or compressed
air foam.
1. Connect the hose(s) to the desired discharge(s).
2. If pumping water from an on board booster tank, fully open the tank to pump
valve.
3. If pumping from an overboard source, the tank to pump valve should be fully
closed.
4. Engage the PTO
5. If so equipped, turn on the main power switch to the CAFS unit.
6. Throttle-up to desired pressure.
If pump pressure is absent, it will be necessary to prime the pump.
7. Open desired discharge valve(s) and throttle-up to desired pressure.
CAUTION:
Running the unit with a dry fire pump can cause damage to the pump and
air compressor system.
II. Foam Solution Operations
Follow the instructions above for water pumping operations.
Turn on the foam proportioner to inject foam concentrate into the water stream. Refer
to the foam proportioner operation manual for instructions in the proper operation of
the installed proportioning system.
III. Compressed Air Foam Operations
Follow the instructions above for foam solution operations. Safe operations dictate
the presence of foam concentrate in the water stream prior to the injection of
compressed air. If foam concentrate is not present, a condition known as “slug flow”
will occur. This is where unmixed water and air is discharged through a nozzle in an
erratic manner.
1. Set water discharge pressure at the desired level.
Discharge pressures for compressed air foam operations typically range
between 80 and 120 PSI in a flow state.
NOTE: Compressed air foam does not have the hydraulic characteristics of plain
water or foam solution. Therefore, standard pump hydraulics practices do not
apply to CAFS operations.

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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2. Move Auto-Sync controls to the AUTO position.
Air pressure as shown on the air pressure gauge should rise to within plus or
minus 5% of the water discharge pressure. The Auto-Sync system will
balance the air and water pressures throughout a range of 40 PSI up to 150
PSI. Optimal compressed air foam system performance occurs at discharge
flow pressures of 80-120 PSI.
3. Set proportioner at 0.2% - 0.6% for normal Class A combustibles.
The type and brand of foam concentrate used and the tactical objective,
dictate proportioning rates.
4. Open desired discharge valve(s).
Controlling the amount of foam solution entering the discharge stream sets
the foam expansion ratio. High solution flows restrict the amount of air
admitted and result in lower expansion or “wet” foam. To produce higher
expansion or “drier” foam, simply gate back the amount of solution admitted.
5. Fully open the air valve(s) to the desired discharge(s).
6. Adjust the solution flow to produce the desired foam consistency.
Foam is formed during the transition through the hose. To produce acceptable
finished foam, sufficient hose length must be provided on the discharge. Refer to the
section “Suggested Guidelines for the Production of Mid-Range Compressed Air
Foam”.
WARNING:
Nozzle reaction force is significantly increased at the time the nozzle valve is opened in
compressed air foam operations. OPEN CAFS NOZZLES SLOWLY!
IV.Compressed Air Only Operation
Follow instructions for water pumping operations without opening discharge valves.
Air compressor cooling is via water that is circulated by the fire pump through the
compressor cooler and returned back to the booster tank. During this operation, time
is limited by the amount of available cooling water.
The water in the booster tank will eventually become heat saturated and ineffective at
cooling the air compressor. Watch the compressor temperature gauge closely!
Maximum of 250°F. Compressor system overheat is also indicated by the panel
mounted warning light and alarm.
1. After PTO engagement, ensure that the water pressure as shown on the
panel mounted gauge rises.
2. Move Auto-Sync control to the FIXED position. Air pressure will rise to the
preset pressure setting on the air compressor, approximately 150-PSI with
the engine throttled-up.
3. For lower operating pressures, move the Auto-Sync controls to the AUTO
position and use the engine throttle to control the water pressure / air
pressure
4. Connect the air discharge hose to the fitting on the pump operator’s panel
and open the air supply valve.

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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Extended compressed air only operations necessitate connection of an external
water source to the pump inlet and closing of the tank to pump valve far proper
compressor cooling. In this case, cooling water will flow into the booster tank at 10-
20 GPM, eventually overflowing the tank.
C. Shut-Down Procedure
Close air valve(s)
Turn off Foam proportioner
Flow clear water through discharge hose(s) until no bubbles are present
Close discharge valve(s)
Move Auto-sync controls to: Electric = UNLOAD
Shut system down
After the system is shut down, the compressor system will vent itself, creating an audible hiss
as compressed air is evacuated from the pressure vessel/sump.
WARNINGS
Compressed air can be dangerous. Read and understand the operating
instructions for the Waterous compressed air foam unit and individual components
prior to operating.
DO NOT use the compressed air foam unit as an air source for SCBA or any
breathing air supply.
Discharge outlets that are capped, hose lines that are valved and charged and the
air compressor sump may contain compressed air. Relieve all pressure BEFORE
attempting to remove any caps, fittings, and nozzles or to perform maintenance to
prevent serious personal injury.
Nozzle reaction force is significantly increased at the time the nozzle valve is
opened in compressed air foam operations. OPEN CAFS NOZZLES SLOWLY!
Operating the compressed air foam unit with water and compressed air pumped
through a discharge without foam concentrate will create a potentially dangerous
condition known as "Slug Flow"; where unmixed pockets of water and air are
passed through the nozzle, causing erratic nozzle reaction.
For compressed air foam operations, use only fire hose that is rated at 200 PSI or
higher working pressure.
The unit operator should have a thorough understanding of "Boyle's Law" (The
law of compressed gases) prior to operating the compressed air foam unit.

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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SECTION 2. COMPRESSOR
A. How It Works
The air compressor used in this application is a GHH-RAND OS70, oil flooded rotary screw
type. Rotary screw air compressors are very common in industrial applications. This type of
compressor injects oil into itself, where it lubricates, seals, cools, and silences the
compressor. The oil is then entrained into the air discharge from the compressor. This air/oil
mixture is discharged into a sump tank where most of the oil separates from the air. The oil is
then sent via hydraulic hose to a combination cooler/thermostat/filter unit. It is cooled to
remove compression and friction heat, filtered, and sent to the oil injection port on the
compressor. The cycle is then repeated.
The oil mist that remains in the air stream is recovered by an air/oil separator system. This
system recovers the oil mist in a spin-on cartridge that has a siphon tube that picks up the
recovered oil for return to the air compressor.
A modulating inlet valve controls the compressor’s air output. The inlet valve is opened and
closed by the Auto Sync pressure control system.
The compressor cooling system circulates water from the fire pump through the compressor
oil cooler and back to the tank to remove heat from the compressor oil system. The
compressor oil temperature should not exceed 250°F. If this occurs, check the water supply;
pump prime, restrictions in the cooling water system and for low oil level in the sump.
The air compressor (air end) is mounted to the transmission of a Waterous CLVK single
stage pump and driven by a dry Poly Chain. The pump / air end are PTO driven by the
engine. It is important to ensure that there is a water supply to the pump whenever the
system is running. Pump and/or compressor damage may result from running the pump dry.

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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SECTION 3. SYSTEM SERVICE AND MAINTENANCE
Excessive heat build-up and oil system contamination are most common causes of
compressor system problems and premature wear. With proper operation and maintenance,
the compressor system should far outlast the vehicle it is mounted on. Adherence to the
following guidelines will prevent potentially costly damage.
1. There is a sight gauge provided on the oil reservoir and visible through a hole on the
pump panel. The oil level should be at approximately halfway up the window. Cheek the
oil on level ground, prior to system start up. If the system has recently been run, wait 10
minutes after shutdown for the oil to stabilize before checking the oil level. The oil should
be checked daily or before or after every use. The compressor uses common hydraulic
oil. This oil is classified by an ISO standard as ISO 68 viscosity and is sold under various
trade names. Many are sold as in “anti wear” hydraulic oil and area available from auto
parts or lubricating oil suppliers.
2. The oil should be changed after the first 30 hours of system operation. After that, the oil
should be changed annually. There is a drain plug located at the bottom of the sump. The
oil fill cap is located on top of the unit.
3. Change the compressor system oil filter at the same time as the oil is changed. The spin-
on filter cartridge is a Mann-Hummel hydraulic oil filter.
4. Run the compressor for 2 minutes after changing the oil, then re-cheek the oil level and
add oil as necessary. DO NOT OVERFILL.
5. Visually inspect the compressor oil system weekly for signs of leaks. Check the air
compressor Poly Chain drive for proper tension and signs of wear monthly or more
frequently as dictated by the amount of use.
6. Proper tension on the Poly Chain is to a no slack setting or slightly loose (about 3/8” - If in
doubt, do not tighten the Poly Chain). A slightly loose Poly Chain is acceptable. An over-
tightened Poly Chain may cause equipment failure, and may void the product warranty.
7. Inspect the compressor air intake filter and clean or replace as necessary. The
environment in which the unit operates will determine the frequency of air filter service
and replacement. In any situation, replace no less frequently than yearly.
8. Replace the oil / air separator cartridge every 24 months, or if the unit’s oil consumption
suddenly increases. A sudden increase may be caused by a hole in the internal media of
the cartridge allowing oil to carry through and discharge with the compressed air.
9. Completely drain the water from the compressor oil cooler in cold weather to prevent
freeze damage.

Waterous Arizona Operations 500-100 & 120-P Operations Rev 1
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A. Maintenance Schedule
Check Oil
Level & for
Oil Leaks
Change
Compressor
Oil
Change
Oil
Filter
Change
Separator
Cartridge
Daily or After
Each Use
X
Annually
X
X
Every 24 Months
X
Refer to the Engine Manual for recommended engine maintenance.
B. Maintenance Items
COMPRESSOR
Part#
AIR FILTER:
CO85004(1)
2030042
SEPARATOR FILTER:
LB 1374/2(2)
0390092
HYDRAULIC FILTER:
WD 920(2)
2030058
HYDRAULIC OIL
ISOAUW68 Anti-Wear, Low-Foaming, Anti-Foaming
BELTS
Part#
POLY CHAIN:
8MGT-1000-36(3)
1030014
(1) = Donaldson (2) = Mann & Hummel (3) = Gates