Waterous AQUIS ULTRAFLOW Installation and operating instructions

AQUIS ULTRAFLOW Industrial Foam Proportioner
Installation, Operation, and Maintenance
Form Number: F-2826 Issue Date:
Revision Date:
Waterous Company • 125 Hardman Avenue South • South Saint Paul, MN 55075 • [phone]
www.waterousco.com

Table of Contents
Safety 9
Safety Precautions 9
Introduction 12
Using this Document 12
Viewing the Document Electronically 12
Printing the Document 12
Product Overview 13
AQUIS ULTRAFLOW Industrial Foam Proportioner System 13
System Components—Tellurus HMI 17
System Components—Control Box 21
System Components—PDM Control Box Connectors 23
System Components—Node Controller 25
System Components—2 inch Valve Assembly 27
System Components—1 inch Valve Assembly 29
System Components—Optional 1 inch Recirculation Line Assembly 31
System Components—Priming Valve Assembly 33
System Components—Concentrate Pump Assembly 35
System Components—Hydraulic Motor 37
System Components—Spider Coupler 39
System Components—Hydraulic Pump 41
System Components—Hydraulic Oil Heat Exchanger 43
System Components—Hydraulic Oil Reservoir 45
System Components—Hydraulic Reservoir Level Sensor 47
System Components—Hydraulic Reservoir Temperature Sensor 49
System Components—Suction Strainer 51
System Components—Hydraulic Oil Filter Components 53
System Components—Paddlewheel Flowmeter 55
System Components—2 inch Magnetic Flowmeter 57
System Components—1 inch Magnetic Flowmeter 59
System Components—6 Inch Concentrate Strainer 61
System Components—Pressure Relief Valve 63
System Components—Water Pump Pressure Sensor 65
System Components—Hydraulic Oil Cooler Thermal Controller 67
System Components—Concentrate Supply Level Switch 69
System Components—Optional Manual Override Switch 71
System Components—Optional Manual Override Relay 73
System Components—Split CANbus Cable 75
System Components—Terminal Resistor 76
System Components—0.5 Meter CANbus Cable Extension 77

System Components—2.0 Meter CANbus Cable Extension 78
System Components—0.5 Meter M12 Cable Extension 79
System Components—3.0 Meter Cable Extension 80
System Components—Manual Override Switch Cable Extension 81
System Components—Manual Override Relay Cable 82
System Components—Concentrate Pump Speed Sensor Cable 83
System Components—Hydraulic Pump Swashplate Control Cable 84
System Components—DLA Control Valve Cable 85
System Components—Priming Valve Motor Cable 86
System Components—Tellurus HMI Cable Assembly 87
System Components—Display Extension Cable 88
Installation 89
Installation Overview 89
Preparing for the Installation 89
Modifying the Equipment 89
Determining Panel and Plate Locations 90
Determining Hose Routing 90
Determining Cable and Wire Routing 90
Main Components—Overview 91
Electrical Connections—Overview 93
Hydraulic Components—Overview 95
Hydraulic Hoses—Overview 97
Plumbing and Components—Overview 99
Wiring the Source-Select Switch 101
Installing the DLA Identication Labels 102
Connecting the 1 Inch DLA 103
Connecting the 2 Inch DLA 104
Connecting Pump Discharge-Pressure Sensor 105
Connecting the Priming Valve 106
Connecting the 1 Inch Low Flow Bypass Line—Optional 107
Connecting the Supply Tank Fill Line 108
Connecting the Tellurus Display 109
Connecting the Concentrate Supply Level Sensors 110
Connecting the Concentrate Pump, Pressure Sensor, and Source Select Valve 111
Connecting the Hydraulic Reservoir Sensors, Suction Strainer, and Hydraulic Pump 112
Connecting the Hydraulic-Oil Cooler and Controller 113
Installing the Hydraulic Motor and Concentrate Pump 114
Connecting the Manual Override—Optional 115
Conguring the System 116
Entering the Conguration Desktop 118

Calibrating the Touchscreen 119
Understanding the Service Menu 120
Defualt 120
Help 121
Exit 122
Ticket 123
Connect 124
Manual 125
Status 126
Show 127
Patch 128
Understanding the Conguration Menu 129
Default 129
Help 130
Help 131
Exit 132
MFG 133
Show 134
Set 135
Image 136
Backup 137
Restore 138
Net 139
Mode 140
Understanding the Network Settings Menu 141
Default 141
Help 142
Exit 143
Enable 144
Disable 145
Client 146
Hotspot 147
Pass 148
Zone 149
Connect 150
Log 151
Scan 152
Save 153
Delete 154

Understanding the Maintenance Menu 155
Default 155
Help 156
Exit 157
Mode 158
Status 159
Backup 160
Restore 161
Patch 162
PLC 163
ORB 164
Diag 165
Cal 166
Log 167
Scan 168
Reset 169
Term 170
Restart 171
Understanding the Calibration Menu 172
Default 172
Help 173
Exit 174
Setting the CAN Node and Valve Address 175
Calibrating the Paddlewheel Flowmeter 176
Operating a DLA Manually 177
Understanding the Operation Menu 178
Default 178
Help 179
Exit 180
App 181
Usage 182
Life 183
Status 184
Log 185
Scan 186

Understanding the Command Menu 187
Default 187
Help 188
Exit 189
Report 190
Service 191
Cong 192
Maint 193
Cal 194
Net 195
Term 196
Patch 197
Restart 198
Powering Up the Display 199
Dening the DLA Gauge Screen 200
Dening the Solution Screen—Buttons 201
Dening the Solution Screen—Telemetry 202
Dening the System Screen—Buttons 203
Dening the System Screen—Telemetry 204
Enabling and Disabling a DLA—Screen Views 205
Adjusting the Solution Screen 207
Switching the Concentrate Source—Screen View 208
Relling the On-Board Supply Tank—Screen View 210
Manually Priming the Concentrate Line 212
Transferring Concentrate 213
Relaying Concentrate 214
Maintenance 215
Maintenance Schedule 215

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Safety Precautions
• Read and understand all the associated documentation before you begin the
installation.
• Read and understand all the notices and safety precautions.
• Be aware that these instructions are only guidelines and are not meant to be
definitive. Contact Waterous when you have questions about installing,
operating, or maintaining the equipment.
• Do not install the equipment if you are not familiar with the tools and skills
needed to safely perform the required procedures—proper installation is the
responsibility of the purchaser.
• Do not operate the equipment when safety guards are removed.
• Do not modify the equipment.
• Regularly check for leaks, worn, or deteriorated parts.
NOTICE
Modifying the equipment
can damage components
and void your warranty.
•
Do not modify the system
or any of its components.
•
Modification
NOTICE
Before Operation
• Read and understand all
the instructions provided.
• Check all fluid levels
and replenish if necessary.
• Remove all shipping plugs
and install the operation
plugs or caps.

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NOTICE
Do not allow fluid in the
lines to freeze.
•
Remove all freezable fluid
from the lines before
storing the apparatus.
•
Freeze Damage
Do not touch the surface
during operation––allow
it to cool after operating.
Hot surface can burn you.
Hot Surface
•
•
Drain the pump after use
and before servicing.
Liquid ejected at high
pressure can cause
serious injury.
High Pressure
•
•
Do not operate beyond
recommended pressure.
Liquid ejected at high
pressure can cause
serious injury.
High Pressure
•
•

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  Product Overview  Operation 
Keep clear of moving
parts when the equipment
is operating.
Rotating parts can cause
severe injury or death
Moving Parts
•
•
Purge all pressure before
servicing.
Liquid ejected at high
pressure can cause
serious injury.
High Pressure
•
•

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  Product Overview  Operation 
Use this document to install and operate your Waterous equipment. Understand
the following conditions before continuing with the document:
• The instructions may refer to options or equipment that you may not have
purchased with your system.
• The illustrations in this document are intended to convey concepts. Do not
use the illustrations to determine physical attributes, placement, or
proportion.
• Understand that your application may require additional steps, that are not
described in the illustrations or instructions, to perform the installation.
• The equipment described in this document is intended to be installed by a
person or persons with the necessary skills and knowledge to perform the
installation.
• The equipment described in this document is intended to be operated by a
person or persons with the basic knowledge of operating similar equipment.
• The information in this document is subject to change without notice.
This document is divided into the following sections:

This section describes general precautions and alert symbols that are in this
document.

This section is an overview of the document.

This section describes the components that make-up the system.

This section describes the installation and initial setup procedures.

This section describes the equipment operation.

This section describes maintenance procedures.
Using this Document
Use the guidelines below when viewing this document.
Viewing the Document Electronically
• View this document in landscape orientation.
• Use the table of contents to navigate directly to that section.
• Text with this appearance is linked to a reference.
Printing the Document
• The document is viewed the best when printed in color.
• The print on both sides and flip on long edge features can provide the
best results.
• Use a 3-ring binder to store the document.

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AQUIS ULTRAFLOW Industrial Foam Proportioner System
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AQUIS ULTRAFLOW Industrial Foam Proportioner System
The AQUIS ULTRAFLOW industrial foam proportioner system supplies concentrate into a solution-capable discharge line. A Tellurus™ touchscreen display,
human machine interface (HMI), shows system activity, and provides control over the system. The HMI uses CANbus protocol to monitor and govern the system.
Foam concentrate is sourced from an on-board tank or an external container. The concentrate pump distributes concentrate though the discharge line assembly
(DLA) using hydraulic components, where it is measured, controlled, and introduced into the solution-capable discharge line to produce foam solution.
SubsystemSubsystem DescriptionDescription
1Control system This monitors and controls the foam proportioning system. The components in this subsystem include:
• Tellurus display (HMI)—this displays system operation and provides control of the system.
• Control box—this connects to various components in the system and contains the programmable logic controllers (PLC).
• Manual override switch, optional—this disables the automatic control of the concentrate control valves.
• Power disconnect relay, optional—this power relay enables and disables power to the DLA.
• Remote I/O, optional—this adds a node controller to the system for additional options required in your application.
• Various cables and wire harnesses—these provide communication and power to system components.
2 Discharge line assembly This manages the concentrate injected into the solution-capable discharge. The system can control up to 16 DLAs. The
components in this subsystem contains:
• Node controller—this connects to, and controls, the concentrate control valve, reads the owmeters and the discharge
pressure transducer.
• CANbus splitter and cable—this passes CANbus bus commands to the next node controller in the chain.
• DLA terminating resistor—this terminates the CANbus connection on the last node controller in the CANbus chain.
• Concentrate control valve—this controls the concentrate flow.
• Magnetic flowmeter—this measures the concentrate flow.
• Check valve—this prevents improper fluid flow in the line.
3Solution-capable discharge This includes the installer supplied water pump, distribution manifold, plumbing, and additional components that produces
water flow. Additional components in this subsystem include:
• Paddlewheel flowmeter—this measures the amount of water flowing in the discharge.
• Water pressure transducer—this measures the water pump discharge pressure.
• Discharge pressure transducer, optional—this measures the individual discharge injection pressure.

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AQUIS ULTRAFLOW Industrial Foam Proportioner System
SubsystemSubsystem DescriptionDescription
4Concentrate pump These components support, control, and power the concentrate pump. The components in this subsystem include:
• Hydraulic concentrate pump—this circulates the foam concentrate through the system.
• Hydraulic motor—this drives the concentrate pump.
• Hydraulic pump—this drives the hydraulic motor.
• Hydraulic ATF reservoir—this contains the hydraulic oil supply.
• Hydraulic ATF filter—this filters the hydraulic oil.
• Hydraulic ATF cooler—this cools the hydraulic oil.
• Hydraulic ATF temperature sensor—this monitors the hydraulic ATF temperature.
• Hydraulic ATF level sensor—this monitors the hydraulic oil level in the reservoir.
• Pressure sensor—this monitors the pressure in the concentrate line.
• Pressure relief valve—this opens when the pressure in the line reaches a predetermined set-point.
5Concentrate supply This contains components that contain or supply foam concentrate for the system. The components in this subsystem
include:
• Foam concentrate supply tank—this contains the on-board foam concentrate supply.
• Tank-full sensor—this indicates a tank full condition to the system.
• Tank-low sensor—this indicates a tank low condition to the system.
• Tank level sensor—this is an installer supplied sensor and display that indicates the supply level in the tank.
• Concentrate pump intake select valve—this is an installer supplied, 2 position valve, and additional components that
sources concentrate from an on-board tank or an off-board supply. A signal is provided to the system to ignore the on-
board tank sensors when sourcing concentrate from an o󰀨-board supply.
• Concentrate strainer—this collects debris that would otherwise flow through the system.
6 Supply tank fill line This allows you to fill the on-board tank from an external source. The components in this subsystem include:
• Node controller—this connects to the fill valve and flowmeters.
• Fill line control valve—this controls the flow of concentrate.
• Magnetic flowmeter—this measures the flow of concentrate.
• CANbus splitter and cable—this connects the node controllers to one another
• Check valve—this prevents improper fluid flow in the line.

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AQUIS ULTRAFLOW Industrial Foam Proportioner System
SubsystemSubsystem DescriptionDescription
7Low-flow circulation line This optional line balances the concentrate supply lines when the flow is lower then the minimum concentrate pump flow
specification—30 gpm (114 L/min). The components in this subsystem include:
• Node controller—this connects to the low-flow control valve, flowmeters.
• Low-flow circulation valve—this controls the flow of concentrate.
• Magnetic flowmeter—this measures the flow of concentrate.
• CANbus splitter and cable—this connects the node controllers to one another.
8 Transfer line This allows you to transfer or relay concentrate from the apparatus to another location. The components in this subsystem
include:
• Node controller—this connects to and controls the concentrate control valve, flowmeters.
• CANbus splitter and cable—this passes CANbus bus commands to the next node controller in the chain.
• Concentrate control valve—this controls the concentrate flow.
• Magnetic flowmeter—this measures the concentrate flow.
• Check valve—this prevents improper fluid flow in the line.
9Priming line This evacuates air from the concentrate pump inlet as the system primes before operation. The components in this
subsystem include:
• Priming valve—this opens to allow air to evacuate the line before operation.
• CANbus splitter and cable—this connects to the valve to control its operation.

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System Components—Tellurus HMI
The Tellurus display, or HMI, displays current operations and provides operator control over the system.
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1
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86
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83826

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System Components—Tellurus HMI
FeatureFeature DescriptionDescription
1Reset button This indicates system status and allows the operator to reset the HMI.
2 Tellurus display—HMI This displays operations and system controls.
3Mounting knob This secures the HMI to the apparatus.
4Mounting bracket This secures the HMI to the apparatus.
5RJ45 connector This connects to a secondary HMI or truck Ethernet network.
6 WIFI connector This connects to a WIFI antenna for wireless access.
7 GPIO connector This connects external power and the control box.
8 GPS connector This connects to the GPS antenna for location information.
9 USB connector This connects a USB keyboard or ash drive for system conguration and updates

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System Components—Tellurus Antenna
The Tellurus antenna receives WiFi and GPS signals.
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8410009

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System Components—Control Box
FeatureFeature DescriptionDescription
1Antenna This receives the WiFi and GPS signals.
2Nut cover This secures the antenna to the apparatus.
3 GPS connector This connects to the GPS connector to the Tellurus HMI.
4WiFi Connector This connects to the WiFi connector to the Tellurus HMI.