AQUASTORM 100™ AND 200™ INSTALLATION MANUAL

AQUEOUS CLEANING SYSTEM

AQUASTORM 100™ AND 200™ INSTALLATION MANUAL

Manual Part #3-9317-520-00-0

Hwy. 5 South, Box 709 | Camdenton, MO 65020 Tel: 573-346-3341 | Fax: 573-346-6878

Speedline Technologies, Inc.

Aquastorm 100™ & Aquastorm 200™

ii 2-9317-520-00-0 — Rev. 1 Installation Manual


Installation Manual 2-9317-520-00-0 — Rev. 1 iii

AQUEOUS CLEANING SYSTEM

AQUASTORM 100™ AND 200™ INSTALLATION MANUALManual Part #3-9317-520-00-0, Revision 1

Text Part #2-9317-520-00-0, Revision 1Copyright© 1999 Speedline Technologies, Inc.

This manual may not be reproduced, stored in a retrieval system, or transmitted in part or in whole. Photocopyting, recording, or other forms of reporduction is prohibited without written permission of Thermal Systems.

Published April 23, 1999


iv 2-9317-520-00-0 — Rev. 1 Installation Manual


Installation Manual 2-9317-520-00-0 — Rev. 1 v

TO OUR CUSTOMERSThe purpose of this manual is to help obtain the greatest possible return on your investment. It is suggestedthat new operators study the applicable sections of this manual thoroughly before operating the equipment.It is futher suggested that the manual be used as a reference by maintenance personnel and as a text fortraining of new maintenance personnel.

This manual includes operating instructions for this equipment available at the time this manual wasapproved for printing. Speedline ELECTROVERT reserves the right to make changes in design andspecifications and/or make improvements in the product without imposing any obligations upon itself toinstall them on previously manufactured products.

SPEEDLINE ELECTROVERT SALES AND SERVICES OFFICES

Speedline ELECTROVERT Customer Support Hot Line

Tel: 800-737-8110

Speedline Technologies, Inc. Main Offices

Product & Technology CenterSpeedline ELECTROVERTP.O. Box 709Camdenton, MO 65020Fax: 573-346-6878Tel: 972-606-1900

24 hr Technical Service Support/Repair PartsSpeedline ELECTROVERTP.O. Box 709Camdenton, MO 65020Fax: 573-346-0002 or 573-346-6878Tel: 800-737-8110 or 573-346-3341e-mail:[email protected]

Field Service Dispatch CenterU.S., Mexico, and Central AmericaSpeedline Technologies580-A Tollgate RoadElgin, IL 60123Fax: 847-289-3797Tel: 800-498-2429 or 847-695-5750

World Wide Training CenterSpeedline Technologies580-A Tollgate RoadElgin, IL 60123Fax: 847-289-3797Tel: 800-498-2429 or 847-695-5750

Regional Service Centers

North East Regional Service Center472 Amherst St. Suite 6Nashua, NH 03063Fax: 603-880-8757Tel: 603-883-2488

South East Regional Service Center200 Technology Dr.Alpharetta, GA 30005Fax: 770-442-1987Tel: 770-475-6100

North Central Regional ServiceCenter580-A Tollgate RoadElgin, IL 60123Fax: 847-289-3797Tel: 847-695-5750

North West Regional Service Center2968 Scott Blvd.Santa Clara, CA 95054Fax: 408-727-0672Tel: 408-727-4650

South West Regional Serv iceCenter1111 W. North Carrier ParkwayGrand Prairie, TX 75050Fax: 972-606-1700Tel: 972-606-1900

International Service Centers

Northern Europe & U.K.Electrovert U.K. Ltd.The Technology CentreUnit 1, Pincents Kiln Industrial ParkPincents KilnCalcot, ReadingBerkshire, U.K. RG31 7SDFax: 44 11-8-930-1401Tel: 44 11-8-930-1400

Speedline Technologies Asia150 Kampong Ampat#05-08 KA CentreSingapore 368234Fax: 65-289 9411Tel: 65-286 6635

JapanElectrovert-Seitec Co., Ltd.1538 Kanoya-choHachioji City, Tokyo 193 JAPANFax: 81-426-23-8350Tel: 81-426-23-7722

Northern EuropeSpeedline Technologies S.A.R.L.65 Avenue du General De GaulleImmeuble le Promethee77420 Champs-Sur Marne, FranceFax: 33 160-05-6129Tel: 33 160-06-8181

Central EuropeSpeedline Technologies, GmbhDaimlerstrasse 1ED-63303Dreieich, GermanyFax: 49 6103-832119Tel: 49 6103-8320Speedline Technologies ItalyVia Liguria 2/28I-20068 Peschiera Borromeo (MI)ItalyFax:39- 2 - 5530.8468Tel: 39- 2 - 5530.8339


vi 2-9317-520-00-0 — Rev. 1 Installation Manual


Installation Manual 2-9317-520-00-0 — Rev. 1 vii

EQUIPMENT MANUAL QUESTIONNAIREThe purpose of this questionnaire is to provide feedback from our customers regarding the effectiveness of the equipment manuals. Please complete the following questions and return to Speedline/ELECTROVERT. Your comments are appreciated.

Customer _______________________________________________________________________________________Address ________________________________________________________________________________________Contact ________________________________________________Date____________________________________Machine Type ___________________________________________Manual Part Number______________________Translated Manual Language ______________________________ Part Number_____________________________Option Manual __________________________________________Part Number_____________________________1. How often do you refer to the technical manual package?

q Frequentlyq Occasionallyq Seldomq Never

2. In what instances do you refer to the technical manual package?q To verify process informationq To reference procedures (operational, maintenance)q To order/identify partsq Other (please specify) ____________________________________________________________________

3. How do you rate the overall layout of the manual package?q Information easy to findq Information difficult to findq If difficult, please explain__________________________________________________________________

4. How do you rate our manuals in comparison to your other capital equipment suppliers?q Higher qualityq Same general qualityq Lower quality

If same general or lower quality, please explain _______________________________________________________________________________________________________________________________________________________

5. How do you rate the accuracy of the technical information?q Very accurateq Somewhat accurateq Not accurateq Can you provide examples, with page number indicated? ______________________________________

_______________________________________________________________________________________6. What tools would make the manuals easier to use and/or find information?

q Indexesq Glossariesq Improved Table of Contentsq Other __________________________________________________________________________________

7. Who are the main users of your equipment manuals?q Operatorsq Maintenance personnelq Process Engineersq Other __________________________________________________________________________________

8. How do you rate the quality of the language translation (if applicable)?q Very accurateq Somewhat accurateq Not accurate

If somewhat or not accurate, can you elaborate?____________________________________________________________________________________________________________________________________________________________________________________________________________________________

Please add any additional comments about our manuals on the back of this page. Please return to:

Technical Publications Department at the address listed below

Hwy. 5 South, Box 709 | Camdenton, MO 65020 Tel: 573-346-3341 | Fax: 573-346-6878

Speedline Technologies, Inc.


viii 2-9317-520-00-0 — Rev. 1 Installation Manual


Installation Manual 2-9317-520-00-0 — Rev. 1 ix

The serial tag information is to be filled by the user for technical support purposes. Please have the followinginformation available when contacting Technical Support or when placing parts orders:

Machine NameModel Number

Mechnical and Electrical Serial NumbersItem/Kit Description


x 2-9317-520-00-0 — Rev. 1 Installation Manual


Installation Manual 2-9317-520-00-0 — Rev. 1 xi

COMMON SAFETY WARNING LABELSThe following warning labels are used throughout this manual:

Notes point out informationin this manual that may be ofassistance to the operation

or maintenance of the machine.

Caution notices areused in this manual toca l l a t tent ion to a

situation that could cause damage toequipment.

Warning notices areused in this manual toemphasize hazardous

vol tages, h igh temperatures, h ighcurrents, or other conditions that couldcause personal injury.

Danger notices areused in this manual towarn the operator that

DEATH may result if a procedure isomitted or improperly performed.


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Installation Manual 2-9317-520-00-0 — Rev. 1 xiii

Table of ContentsAquastorm 100™ and Aquastorm 200™

Combined Installation Manual

To our Customers ..................................................................................................................................................vSpeedline Electrovert Sales and Services Offices .............................................................................................vEquipment Manual Questionnaire ......................................................................................................................viiCommon Safety Warning Labels .........................................................................................................................xi

SECTION 1: SAFETY INFORMATIONSECTION 1.1: HAZARDS.........................................................................................................................................1SECTION 1.2: SAFETY PRECAUTIONS...................................................................................................................2SECTION 1.3: LOCK OUT-TAG OUT ........................................................................................................................3

Initial Preparation .................................................................................................................................................3Lock Out Main Power Switch...............................................................................................................................4

SECTION 1.4: PERFORM MAINTENANCE ............................................................................................................5SECTION 1.5: RESUME/BEGIN OPERATION ........................................................................................................5

REmove Lock Out Device .....................................................................................................................................5

SECTION 2: TECHNICAL DATASECTION 2.1: FACILITY REQUIREMENTS..............................................................................................................7

Water Requirements.............................................................................................................................................7Final Rinse .............................................................................................................................................................7Fill ...........................................................................................................................................................................7System Drain.........................................................................................................................................................7Exhaust Requirements .........................................................................................................................................7Capacities ..............................................................................................................................................................8Specifications........................................................................................................................................................8

SECTION 2.2: AQUASTORM 200™ ELECTRICAL REQUIREMENTS....................................................................9Standard Configuration........................................................................................................................................9Optional Configuration.........................................................................................................................................9Pump and Blower Upgrade Level 1 .....................................................................................................................9Pump and Blower Upgrade Level 2 .....................................................................................................................9Enclosed CLS ........................................................................................................................................................9Calculation for FLA ...............................................................................................................................................10

SECTION 2.3: AQUASTORM 200™ DIMENSIONS................................................................................................11SECTION 2.4: AQUASTORM 100™ ELECTRICAL REQUIREMENTS....................................................................14

Standard Configuration........................................................................................................................................14Optional Configuration.........................................................................................................................................14Pump and Blower Upgrade Level 1 .....................................................................................................................14Pump and Blower Upgrade Level 2 .....................................................................................................................14Enclosed CLS ........................................................................................................................................................15Calculation for FLA ...............................................................................................................................................15

SECTION 2.5: AQUASTORM 100™ DIMENSIONS................................................................................................16


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SECTION 3: INSTALLATION PREPARATIONSECTION 3.1: RECEIVING INSTRUCTIONS........................................................................................................... 19SECTION 3.2: INSTALLATION PLANNING ............................................................................................................ 19SECTION 3.3: INSTALLATION CHECK LIST .......................................................................................................... 20SECTION 3.4: AQUASTORM 200™ SYSTEM FOOTPRINT DRAWINGS .............................................................. 21SECTION 3.5: AQUASTORM 100™ SYSTEM FOOTPRINT DRAWINGS .............................................................. 23

SECTION 4: EQUIPMENT AND TOOLS REQUIREDSECTION 4.1: PROTECTIVE CLOTHING................................................................................................................. 27SECTION 4.2: TOOLS AND MATERIALS................................................................................................................ 27

International Shipments ...................................................................................................................................... 27SECTION 4.3: EXPENDABLE ITEMS...................................................................................................................... 27SECTION 4.4: RIGGING EQUIPMENT .................................................................................................................... 27

Domestic Shipments ........................................................................................................................................... 27International Shipments ...................................................................................................................................... 27

SECTION 4.5: MAINTENANCE ............................................................................................................................... 27

SECTION 5: SHIPPING ARRANGEMENTSECTION 5.1: SHIPPING WEIGHTS AND DIMENSIONS..................................................................................... 29

Aquastorm 200™ Domestic Shipment Dimensions.......................................................................................... 29Aquastorm 100™ Domestic Shipment Dimensions.......................................................................................... 29

SECTION 5.2: PACKAGE CONFIGURATIONS ....................................................................................................... 30Domestic Shipments ........................................................................................................................................... 30Documentation Package ..................................................................................................................................... 31International Shipments ...................................................................................................................................... 32Documentation Package ..................................................................................................................................... 33

SECTION 6: DOMESTIC UNPACKING PROCEDURESSECTION 6.1: LOCATE AND LEVEL THE SYSTEM ................................................................................................ 35

Leveling feet .......................................................................................................................................................... 35SECTION 6.2: CABINET LEVELING PROCEDURE ................................................................................................ 36SECTION 6.3: REMOVING SYSTEM PACKING MATERIALS ................................................................................ 38SECTION 6.1: INSTALLING THE DRAIN SCREENS .............................................................................................. 40SECTION 6.2: PUMP DRAIN PLUG........................................................................................................................ 42

SECTION 7: INTERNATIONAL UNPACKING STEPSSECTION 7.1: INITIAL PREPARATION AND CRATE REMOVAL .......................................................................... 43SECTION 7.2: INSTALLING THE SYSTEM LEVELING FEET................................................................................... 45SECTION 7.3: POSITIONING THE SYSTEM ........................................................................................................... 46SECTION 7.4: CABINET LEVELING PROCEDURE ................................................................................................ 46SECTION 7.5: REMOVING SYSTEM PACKING MATERIALS ................................................................................ 48SECTION 7.1: INSTALLING THE DRAIN SCREENS .............................................................................................. 50SECTION 7.2: PUMP DRAIN PLUG........................................................................................................................ 52

SECTION 8: INSTALLING OPTIONSSECTION 8.1: LIGHT TOWER .................................................................................................................................. 53SECTION 8.2: SUMP PUMP ................................................................................................................................... 53

Sump Pump Installation ...................................................................................................................................... 54SECTION 8.3: TREATMENT INTERFACE................................................................................................................ 54

Treatment Interface System Installation............................................................................................................. 55SECTION 8.4: BOLT ON SOUND ENCLOSURE .................................................................................................... 56

Bolt On Sound Enclosure Installation ................................................................................................................ 56


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SECTION 8.5: EXIT CONVEYOR EXTENSION.........................................................................................................57Install Exit conveyor Extension ............................................................................................................................57

SECTION 8.6: INLET CONVEYOR EXTENSION ......................................................................................................58Inlet conveyor Extension Installation ..................................................................................................................58

SECTION 8.7: PHOTOCELL .....................................................................................................................................60Photocell Installation............................................................................................................................................60

SECTION 8.8: CONVEYOR WIRE BELT ..................................................................................................................61Conveyor Wire belt Installation............................................................................................................................61

SECTION 8.9: CHECKMATE™ HOLD DOWN CONVEYOR...................................................................................62Checkmate™ hold down conveyor installation ..................................................................................................62

SECTION 8.10: WIRE BELT SPLICING STEPS .........................................................................................................64Connect Wire Belt LinkS ......................................................................................................................................65

SECTION 9: FACILITY AND POWER CONNECTIONSSECTION 9.1: FACILITY WATER HOOK-UP............................................................................................................69

Water Supply .........................................................................................................................................................69Connect the Plumbing .........................................................................................................................................69Rinse Hose ............................................................................................................................................................70

SECTION 9.2: FACILITY EXHAUST HOOK-UP .......................................................................................................70Connect the exhaust.............................................................................................................................................70

SECTION 9.3: CONNECT FACILITY POWER...........................................................................................................71System Grounding ................................................................................................................................................71Connect System Power ........................................................................................................................................72

SECTION 9.4: SYSTEM ELECTRICAL CHECK ........................................................................................................73Main Power Check................................................................................................................................................73Secondary Voltage Check ....................................................................................................................................73

SECTION 9.5: MOTOR ROTATION CHECK............................................................................................................76Blower Motor Rotation Check..............................................................................................................................76

SECTION 9.6: REPLACE BLOWER BELT ...............................................................................................................79SECTION 9.7: ADDITIONAL INFORMATION .........................................................................................................80


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Installation Manual 2-9317-520-00-0 — Rev. 1 1

SECTION 1: SAFETY INFORMATION

1.1 HAZARDSOperation of this equipment exposes personnelto potential health hazards.

Risk of Electric Shock —Ins ta l l a t ion o f th i sequ ipment invo l ves

exposure to situations which may result inelectrical shock if procedures are not properlyfollowed. Pay close attention to Warnings ofthis nature throughout the context of thismanual.When performing tests using ammeters, voltmeters, or ohm meters, electrical shock hazardis present . These procedures must beperformed only by an authorized electrician,electrical engineer, or service technicianfamiliar with testing live voltage.

HIGH VOLTAGE —I ns ta l l a t i on o f th i sequ ipment invo l ves

exposure to High Voltage. High Voltage canshock, burn, or cause death. Use extremecaution when performing voltage andamperage tests on l ive voltage. Theseprocedures must be performed only by anauthorized electrician, electrical engineer, orservice technician familiar with testing livevoltage.

Skin Irritation — W h e n u s i n g c e r t a i nchemica ls such as

descalers or saponifiers, it is important tofollow the MSDS (Material Safety Data Sheet)guidelines for proper handling and usage.Wear appropriate clothing and safety articleswhen us ing desca le r and sapon i f i e rsolutions. Skin or eye irritation will occur ifnot handled properly.

Hot Sur faces/BurnHazard — During normaloperation this equipment

and some of its components operate attemperatures up to 60–71 °C (140–160 °F).The operator must use extreme caution andwear the recommended safety garmentsprior to coming in contact with hot surfacesor components. Closely follow and adhere tothe Warnings in this manual which pertain tohot surfaces.Use extreme caution when working aroundo r w i t h h o t c o m p o n e n t s . A l l o w h o tcomponents to coo l be fore handl ingwhenever possible.

Heavy Objects — When attempting to moveheavy equ ipment o r

components, it is imperative to use theproper rigging equipment. Do not attempt tomove skids or large assemblies without theuse of a fork lift or other rigging equipment.Hand lifting will cause serious personalinjury.

To avoid damage to theequipment and systemdrain f ix tures located

under the machine, adjust the fork lift forksto their widest position. Use fork extensionson forks if the forks do not extend at leastseven (7) feet. Do not place fork lift forks atthe positions indicated by the CAUTIONlabels. The Aquastorm 200™ and Aquastorm100™ frame width is 153.7cm (59.9 inches).


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1.2 SAFETY PRECAUTIONSElectrical work should only be performed by aqualified electrician.

Prior to applying power for the first time, ensurethat the system is properly grounded.

Post No Smoking signs in the work area andprovide measures for enforcement.

Exercise caution when using strong cleaningagents, solvents, and other chemicals. MSDSguidelines contain specific uses and safetyprecaut ions which must be thoroughlyunderstood and strictly followed. If in doubtabout any sa fe t y no t i ces , con tac t themanufacturer for clarification.

Avoid prolonged skin contact and inhalation ofchemicals and fumes.

Operating this equipment may introduce burnhazards. Avoid contact with all hot surfaces,hot water, and steam. The viewing glass canreach temperatures in excess of 71 °C (160 °F).Take extreme caution to avoid touching theglass surfaces. Water temperatures reach and/or exceed 71 °C (160 °F). Steam may escapefrom the system cabinet when windows areopened during operation or for maintenanceprocedures. Steam causes serious burns. Avoidcontact with steam.

Protective clothing is required for servicing hotmachine components or areas of the machinewh ich come in con tac t w i th chemica lapplications. Protective clothing includes thefollowing approval agency and items:

ANSI (American National StandardInstitute) approved:• Safety GogglesNIOSH (National Institute for OccupationalSafety and Health) ORMSHA (Mine, Safety and HealthAdministration) approved:• Respirator• Steel Toe Safety Shoes• High Temperature, Acid, and Water

Resistant Gloves• Apron• Long-Sleeved garment

Fumes can generate from certain saponifies,defoamers, descalers, cleaning solvents, orother chemicals used during operation. Takeprecaut ions to avo id accumula t ion o fflammable vapors. Whenever harmful fumesare present, a proper extraction (exhaust)sys tem must be prov ided. Refer to themanufacturer MSDS for information and safetyprecautions concerning their products andsystem exhaust specifications.

Refer to specific chemical manufacturersMSDS guidelines for disposal and/or removaland handling of waste materials resulting fromchemical operating processes.

All operators should be provided with an NIOSHor MSHA approved Respirator to provideeffective protection from airborne residueresulting from certain saponifiers, defoamers,descalers, cleaning solvents or other chemicalsused during operation.

The chemicals and cleaningagents recommended for usewith Aquastorm systems are not

products of Electrovert. Please refer to thespecific chemical manufacturer MaterialSafety Data Sheet (MSDS) for specific use,handling, and safety procedures for chemicaland cleaning agent applications.



1.3 LOCK OUT-TAG OUTBe sure to perform Lock Out – Tag Out stepsbefore beginning maintenance, installation, orupgrade procedures. Refer to the followingsteps when performing any maintenance,installation, or upgrade procedures on anAquastorm 100™ or Aquastorm 200™ System:

1. Identify the types of energy sources used,potential hazards, and all control devices.

2. Notify all affected employees.

3. Turn off all operating controls.

4. Locate all energy sources.

5. Lock out the main power switch in the OFFposition.

Figure 1: Main Power Switch Location

6. Perform the required task or maintenanceprocedure.

7. Remove lock out device only after theequipment is fully assembled and allaffected employees are notified.

8. The person who attaches a lock out deviceis responsible to remove the device.

INITIAL PREPARATIONBefore beginning maintenance or repairprocedures, be sure to perform Lock Out – TagOut steps.

To prepare for system maintenance:1. Ensure there are no Printed Circuit Boards

(PCB) or other product in the system.

2. Locate the Lower Control Panel at theentrance end of the system.

3. Power down all operating sections of themachine by pressing the Off buttons onthe Lower Control Panel.

Figure 2: Gauge Panel and Control Panel Location (Aquastorm 200™ Shown)

Main Power Switch

Exit End of Machine

UL Tag

Serial Tag

Gauge Panel

Lower Control Panel

Entrance End of Machine



Figure 3: Aquastorm 100™ Lower Control Panel

Figure 4: Aquastorm 200™ Lower Control Panel

LOCK OUT MAIN POWER SWITCH

To attach a lock out-tag out device:1. Locate the main power disconnect switch

at the exit end of the system.

Electrical current usedcan kill. DO NOT TOUCHlive electrical components

inside the electrical enclosure.

2. Turn the main disconnect switch to the OFFposition.

3. Pull the tab and insert the Lock Out device.

4. Secure the Lock Out device in place.

Figure 5: Exit End of Machine

5. On systems with an optional EPS(Emergency Power Supply) battery backupinstalled, toggle the battery control to theOFF position.

6. The system is ready for maintenance onelectrical, and plumbing devices.

ELECTROVERT

ELECTROVERT

Main Power Disconnect

Exit End of Machine



1.4 PERFORM MAINTENANCEProceed with the specif ic maintenance,installation, or upgrade required. Follow thedirections in the manuals supplied with thesystem.

Components in thes y s t e m b e c o m e h o tduring normal system

operation. Heated sections of the machineproduce steam. To prevent burns, allowheated sections or hot components to cool orwear requ i red sa fe t y c lo th ing whenaccessing heated areas of the machine formaintenance.

1.5 RESUME/BEGIN OPERATIONPrior to removing the Lock Out device andresuming system operat ion, ensure thefollowing is complete:

• Perform and complete each scheduledmaintenance, installation, or upgradeoperation

• Replace any worn parts, if necessary• Complete all required cleaning steps, if

necessary• Replace all enclosures removed during

maintenance, installation, or upgrade• Latch or appropriately tighten down all

enclosures removed during maintenance,installation, or upgrade operations

If items removed duringmain tenance a re no tp r o p e r l y r e p l a c e d ,

damage to the equipment can occur.

REMOVE LOCK OUT DEVICEThe person who attaches a lock out device isresponsible to remove the device.

1. At the exit end of the machine unlock thelock out device.

2. Place the Main Power Disconnect in the Onposition.

3. On systems with an optional EPS(Emergency Power Supply) battery backupinstalled, toggle the battery control to theOn position.

Resume normal system operation.






SECTION 2: TECHNICAL DATA

2.1 FACILITY REQUIREMENTSThese general facility requirements pertain toboth the Aquastorm 200™ and Aquastorm100™ systems and cover all possible optionsavailable. During preliminary preparation andsystem set up refer only to those items relatingto the system ordered or purchased.

WATER REQUIREMENTSThe Fill and Final Rinse water supplies must beseparate.

The immersion heaters in the recirculatingwash and rinse tanks will heat incoming tap ortreated water after an initial waiting period.Electrovert recommends supplying heatedwater 60–71 °C (140–160 °F) to the recirculatingwash, rinse, and optional chemical isolationtanks in o rde r to ma in ta in opera t ingtemperatures.

FINAL RINSEUser supplied, heated tap or treated water.

Schedule 80, 3/4 in. NPTCPVC pipe

Temperature 60–71° C (140–160° F)Flow Rate 11–19 L/Min

(3–5 Gal./Min.)

Nominal Pressure 2.8–3.3 kg/cm2

(35–40 PSI)

FILLUser supplied, heated tap or treated water.

Schedule 80, 3/4 in. NPTCPVC pipe

Temperature 60–71° C (140–160° F)

SYSTEM DRAINCommon 1-1/2 in. NPT, CPVC pipeConstant 38 L/Min. (10 GPM)

EXHAUST REQUIREMENTSThe following exhaust specifications assist thecustomer in specifying an exhaust blowercapable of exhausting the system. Measure allexhaust measurements at the machine exhaustport. Proper exhaust is required to ensurecorrect machine operation and safety.

A n i n d e p e n d e n t , s e p a r a t e b l o w e r i srecommended for this equipment due to thehigh volume requirements and condensatebuild up resulting from normal operation.

Contact your local HVAC specialist for blowerrequirements and ventilation hook-up.

Recommended venting material:• 5.4 cm (10 in.) diameter minimum• Seamless stainless steel or PVC air

duct.Total requirements for standard two (2)dryer system:

• 68 M3/min. @ 2.5 cm (2400 SCFM @ 1.0 in.) H2O static pressure

Total requirements for optional add-ondryers numbered three (3) and four (4):

• 102 M3/min. @ 2.5 cm (3600 SCFM @ 1.0 in.) H2O static pressure

Port #1

• 34 M3/min. @ 2.5 cm (1200 SCFM @ 1.0 in.) H2O static pressure.

Port #2


Optional Port #3 and Port #4




CAPACITIESUnless otherwise noted, all options listed areavailable on both the Aquastorm 200™ andAquastorm 100™ systems.

Recirculating Wash Tank

• 300 Liter (80 gallon)

Recirculating Rinse Tank

Available on Aquastorm 200™ systems only.


Optional Enhanced Chemical Isolation Tank



Optional Sump Pump


Optional Treatment Interface Tank

• 66.24 Liter (17.5 gallon)

SPECIFICATIONSThe following specifications cover all possibleoptions and configurations for both theAquastorm 200™ and Aquastorm 100™systems. During system set up refer only tothose items relating to the system ordered orpurchased.

Wash Section

• Standard – 5 HP @ 220 L/Min. (58 gpm)• Hurricane – 10 HP @ 439 L/Min. (116 gpm)• Wash Heaters – Two (2) 16 KW Heaters;

32 KW Total

Optional Chemical Isolation Section


• Enhanced Chemical Isolation Tank Heater –One (1) 16 KW Total

Optional Drag-Out Blower

• 7.5 HP, 3 Ph, 460 VAC, 500 CFM TurbineBlower

Rinse Section

• Standard – 5 HP @ 220 L/Min. (58 gpm)• Hurricane – 10 HP @ 439 L/Min. (116 GPM)• Two (2) 16 KW Heaters 32 KW Total

Dryer #1 Blower

• Standard Turbine Blower – 7.5 HP, 3 Ph, 460 VAC, 500 CFM

• Option 1 Turbine Blower – 10 HP, 3 Ph, 460 VAC, 600 CFM


Dryer #2 Blower

• Standard Turbine Blower – 7.5 HP, 3 Ph, 460 VAC, 500 CFM


Optional Radiant Heater

• Two (2) 1800 Watt Radiant Heater panels;3.6 KW Total

Conveyor

• 1/8 HP, 90 VDC Motor, 0.0–3.65 MPM (0–12 FPM) (0.0–4.57 Meters/Min.)

CheckMate™ Conveyor

• Two (2), 1/8 HP, 90 VDC Motors, 0–15 FPM (0.0–4.57 Meters/Min.)

Sump Pump

• 3/4 HP, 3 pH, 460 VAC, 50 gpm (189 L/Min.)



2.2 AQUASTORM 200™ ELECTRICAL REQUIREMENTS

For systems with 220 V electricalconfigurations, the customer isresponsible to provide a system

electrical disconnect capable of protectingthe Aquastorm 100 ™ or Aquastorm 200™ atthe amperages specified. Systems with 380and 460 V electrical configurations include asystem disconnect.

STANDARD CONFIGURATION• 460 VAC, 3 PH, 60 Hz (214 amps maximum)

Includes system high voltage disconnect

OPTIONAL CONFIGURATION• 220 VAC, 3 PH, 60 Hz (428 amps maximum)

No high voltage disconnect• 380 VAC, 3 PH, 50 Hz (259 amps maximum)


PUMP AND BLOWER UPGRADE LEVEL 1Provides the following upgrades:

Wash or Rinse Section

• Wash and Rinse pumps to 10 HP


• Adds a 7.5 HP Enhanced ChemicalIsolation blower And/Or

• Adds a tank immersion heater.

Dryer Section

• Dryer blowers to 10 HPAnd/Or

• Adds an IR Dryer to Dryer #2





• Adds a tank immersion heater.

Dryer Section

• Adds an IR Dryer to Dryer #2; And/Or

• Upgrades Dryer #2 to 15 HP;

ENCLOSED CLSSpecify the power requirement when orderingan enclosed Closed Loop System (CLS).

Standard Power — 460 VAC, 3 phase, 60 Hz.(40 Amps)

Optional Power — 380 VAC, 3 phase, 50 Hz(48 Amps).



CALCULATION FOR FLA To calculate the FLA (Full Load Amps) for aspecific system configuration, use the followingformula and the specific KVA ratings listed bymodule in Table 1 on page 10.

The normal operating power is 80-8 5 % o f t h e m a x i m u m p o w e rrequired, depending on process

parameters and operational load for theproduct being run.

Total Machine kVA x 1000Amps Required =

(1.732) x (Machine Voltage)

Table 1: Aquastorm 200™ Modules

MODULETOTAL POWER

MODULETOTAL POWER

Controls 3 kVA Add-On Single Dryer (Opt.)7.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Wash ModuleHeaters (2 @ 16 kVA)5 HP Pump (Std.)10 HP Pump (Opt.)

32.kVA5 kVA

10 kVA

Add-On Dual Driver (Opt.) Dual Dryer Module #1

7.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Chemical Isolation Level 1 (Opt.)7.5 HP Blower (Std.) 7.7 kVA

Dual Dryer Module #27.5 HP Blower (Std.)10 HP Blower (Opt.)IR Heaters (Opt.)

7.7 kVA10 kVA3.6 kVA

Enhanced Chemical Isolation Level 2 (Opt.)7.5 HP Blower (Std.) 7.7 kVA

3/4 in. HP Sump Pump (Opt.) 0.83 kVA

Enhanced Chemical Isolation Level 3 (Opt.)7.5 HP Blower (Std.)Single 16 kVA Heater (Std.)

7.7 kVA16 kVA

2 HP Treatment Interface Pump (Opt.) 2.2 kVA

Rinse ModuleHeaters (2 @ 16 kVA)5 HP Pump (Std.)10 HP Pump (Opt.)

32 kVA5 kVA

10 kVA

Dryer Module #17.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Dryer Module #27.5 HP Blower (Std.)10 HP Blower (Opt.)IR Heaters (Opt.)


Enclosed CLS (Requires Separate Power Drop to Heater)

Stand Alone Heater (Std.) 30 kVA

2 HP Pump (Standard) 2.2 kVA



2.3 AQUASTORM 200™ DIMENSIONSStandard System Main Cabinet [Frame]

600 cm (236.38 in.) L x 154 cm (60.51 in.) Wx 128 cm (50.24 in.) H

Standard System Overall Dimensions

Main Cabinet, Control Panel, and Sound Enclosure – 691 cm (272 in.)

Leveling Feet

10.16 cm (4 in.)

Exhaust Vent

5 cm (2.0 in.) from the top of the MainCabinet

Optional Inlet Conveyor

85.8cm (33.8 in.)

Figure 6: Aquastorm 200™ Cabinet Dimensions

Figure 7: Optional Inlet Conveyor (Aquastorm 200™ Shown)

128 cm(50.24 in.)

154 cm(60.51 in.) 600 cm

(236.38 in.)

5 cm(2.0 in.)

691 cm(272 in.)58.9 cm

(23.0 in.)

10.16 cm(4.0 in.)

91.4 cm(36.0 in.)



Optional Add-On Single Dryer Module(Blower #3)

Refer to Figure 8 on page 12. Configured as a third drying station thisadd-on or stand-alone unit measures 79 cm(31 in.) in width and includes:• Temperature monitor via thermocouple

sensor• LCD readout on operator control panel.• Two (2) tubular stainless steel height

adjustable upper airknives.• One (1) fixed lower tubular stainless

steel airknife.• 7.5 HP high-velocity centrifugal blower.

• Air cooled providing 14 m3/min. @ 97cm (500 cfm @ 46 in.) of water.

Blower Upgrade 1• 10 HP high-velocity centrifugal blower

• Air cooled providing 18 m3/min. @ 117cm (600 cvm @ 46 in.) of water.



Airknife Option• Electrosonic™ Air Knife package.

Figure 8: Optional Add-On Dryer Module Drawing

M8 Hex Nut2-9237-006-00-0

M8 Lock Washer2-9233-005-00-0

M8 Flat Washer2-9232-007-00-0

M8 x 50 HexHead Bolt2-9200-053-00-0

M8 Flat Washer2-9232-007-00-0

Bolt Thru Dryer Entrance Bulkheadand Cabinet Exit Bulkhead using M8Hardware (17 Sets)



Optional Add-On Dual Dryer Module (Blower #3 and Blower #4)

Configured as the third and fourth dryingstations this add-on or stand-alone unitincludes two (2) sections measuring 79 cm(31 in.) in width for a total measurement of158 cm (62 in.) wide. Each section includes:• Temperature monitor via thermocouple





Blower Upgrade 1 for Blower #3• 10 HP high-velocity centrifugal blower




Airknife Option for Blower #3• Electrosonic™ Air Knife package.





Airknife Option for Blower #4• Electrosonic™ Air Knife package.Radiant Panel Drying Station for Blower #4• Two (2) 1.8 kW (3.6 kW total) elements

with:One (1) upper panelOne (1) lower panelTemperature monitor and controllerThermocoupleLCD readout capabilities

Optional Status Tower

58.9cm (23.2 in.) from top of Main Cabinet

Optional Treatment Interface System

133.6 cm (52.1 in.) L x 68.3 cm (26.7 in.) Wx 81.62 cm (32.13 in.) H

Optional Sump Pump

61.6 cm (24 in.) L x 42.5 cm (16.6 in.) Wx 61.8 cm (24.1 in.) H

Figure 9: Optional Treatment Interface Dimensions

68.3 cm(26.7 in.)

133.6 cm(52.1 in.)

81.62 cm(32.13 in.)



Figure 10: Optional Sump Pump Dimensions

2.4 AQUASTORM 100™ ELECTRICAL REQUIREMENTS

For systems with 220 V electricalconfigurations, the customer isresponsible to provide a system

electrical disconnect capable of protectingthe Aquastorm 100 ™ or Aquastorm 200™ atthe amperages specified. Systems with 380and 460 V electrical configurations include asystem disconnect.

STANDARD CONFIGURATION• 460 VAC, 3 PH, 60 Hz (214 amps maximum)


OPTIONAL CONFIGURATION• 220 VAC, 3 PH, 60 Hz (428 amps maximum)

No high voltage disconnect• 380 VAC, 3 PH, 50 Hz (259 amps maximum)





Dryer Section

• Dryer blowers to 10 HPAnd/Or

• Add an IR Dryer to Dryer #2




Dryer Section

• Add an IR Dryer to Dryer #2And/Or

• Upgrade Dryer #2 to 15 HP

108.0 mm(4.2 in.)

344.0 mm(13.4 in.)

425.5 mm(16.6 in.)

121.8 mm(4.8 in.)

533.4 mm(20.8 in.)

615.9 mm(24.0 in.)

Sump Outlet1 in. NPTF

494.1 mm(19.3 in.)

618.3 mm(24.1 in.)

368.3 mm(14.4 in.)

73.2 mm(2.9 in.)

Sump Inlet(1-1/2 in. NPTF)

Pump

212.7 mm(8.3 in.)

Electrical Inlet



ENCLOSED CLSSpecify the power requirement when orderingan enclosed Closed Loop System (CLS).

Standard Power — 460 VAC, 3 phase, 60 Hz.(40 Amps)

Optional Power — 380 VAC, 3 phase, 50 Hz(48 Amps).

CALCULATION FOR FLA To calculate the FLA (Full Load Amps) for aspecific system configuration, use the followingformula and the specific KVA ratings listed bymodule in Table 2 on page 15.

The normal operating power is 80-8 5 % o f t h e m a x i m u m p o w e rrequired, depending on process

parameters and operational load for theproduct being run.

Total Machine kVA x 1000Amps Required =

(1.732) x (Machine Voltage)

Table 2: Aquastorm 100™ Modules

MODULETOTAL POWER

MODULETOTAL POWER

Controls 3 kVA Add-On Single Dryer (Opt.)7.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Wash ModuleHeaters (2 @ 16 kVA)5 HP Pump (Std.)10 HP Pump (Opt.)

32.kVA5 kVA10 kVA

Add-On Dual Driver (Opt.) Dual Dryer Module #1

7.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Dryer Module #17.5 HP Blower (Std.)10 HP Blower (Opt.)15 HP Blower (Opt.)

7.7 kVA10 kVA

14.6 kVA

Dual Dryer Module #27.5 HP Blower (Std.)10 HP Blower (Opt.)

7.7 kVA10 kVA

Dryer Module #27.5 HP Blower (Std.)10 HP Blower (Opt.)IR Heaters (Opt.)


3/4 in. HP Sump Pump (Opt.) 0.83 kVA

Enclosed CLS (Requires Separate Power Drop to Heater) 2 HP Treatment Interface Pump (Opt.) 2.2 kVA

Stand Alone Heater (Std.) 30 kVA

2 HP Pump (Std.) 2.2 kVA



2.5 AQUASTORM 100™ DIMENSIONSStandard System Main Cabinet [Frame]

404.8 cm (159.4 in.) L x 157.5 cm (61.4 in.)W x 127.6 cm (49.8 in.) H

Standard System Overall Dimensions

Main Cabinet, Control Panel, and SoundEnclosure – 495.3 cm (194.6 in.)

Leveling Feet

10.16 cm (4 in.)

Exhaust Vent

5 cm (2.0 in.) from the top of the MainCabinet

Optional Status Tower

58.9cm (23.2 in.) from top of Main Cabinet

Optional Inlet Conveyor

Refer to Figure 7 on page 11. 91.4 cm (36.0 in.)

Optional Sump Pump

Refer to Figure 10 on page 14. 61.6 cm (24 in.) L x 42.5 cm (16.6 in.) W x61.8 cm (24.1 in.) H

Figure 11: Aquastorm 100™ Cabinet Dimensions

127.6 cm(49.8 in.)

457.5 cm(61.4 in.)

404.8 cm(159.4 in.)

5 cm(2.0 in.)

552.2 cm(217.4 in.)

58.9 cm(23.0 in.)

10.16 cm(4.0 in.)



Optional Add-On Single Dryer Module(Blower #3)

Refer to Figure 8 on page 12. Configured as a third drying station thisadd-on or stand-alone unit measures 79 cm(31 in.) in width and includes:• Temperature monitor via thermocouple









Airknife Option• Electrosonic™ Air Knife package.

Optional Add-On Dual Dryer Module (Blower #3 and Blower #4)

Refer to Figure 8 on page 12. Configured as the third and fourth dryingstations this add-on or stand-alone unitincludes two (2) sections measuring 79 cm(31 in.) in width for a total widthmeasurement of 158 cm (62 in.). Eachsection includes:• Temperature monitor via thermocouple









Airknife Option for Blower #3• Electrosonic™ Air Knife package.Upgrade Option 1 for Blower #4• 10 HP high-velocity centrifugal blower


Airknife Option for Blower #4• Electrosonic™ Air Knife package.Radiant Panel Drying Station• Two (2) 1.8 kW (3.6 kW total) elements

with:One (1) upper panelOne (1) lower panelTemperature monitor and controllerThermocoupleLCD readout capabilities






SECTION 3: INSTALLATION PREPARATION

3.1 RECEIVING INSTRUCTIONSUpon receipt, thoroughly inspect the system. Ifany damage or loss is detected, enter all detailson the freight bill or receipt, then have it signedby the carrier agent. Failure to follow thisprocedure may result in the carrier's refusal tohonor the claim. The carrier is responsible tofurnish the necessary forms for filing a claim.

When damage is not readily apparent until theequipment has been unpacked, file a claim forconcea led damage . Make a wr i t t en o rtelephone request to the carrier for inspectionas soon as the damage is discovered. This typeof claim must be completed within 48 hours ofdelivery.

Keep all cartons, packing materials andpaperwork . The car r ie r w i l l fu rn ish aninspection report and the necessary forms forfiling the concealed damage claim.

3.2 INSTALLATION PLANNINGAllocate sufficient floor space to operateefficiently and to allow accessibility to thesystem from all sides. Refer to the systemfootprint drawing include in the DocumentationPackage.

D o m e s t i c s h i p m e n t s s h i p o n w h e e l s .International shipments are belted to skids andenclosed in a wooden crate. The systemleveling feet are packaged in the box labeledDocumentation Package Enclosed.

System operation and maintenance functionsrequire additional space for system access.Allow for an additional 9 meters (3 feet)clearance behind and around the system,except where the system is in-line with otherautomated equipment, such as wave or reflowsoldering equipment. Refer to the systemfootprint drawing on the following pages.

In selecting a site location, keep in mind theelectrical access, facility exhaust, drain, levelsurface, and other related requirements.

When considering a site for installation, checkthe flammability of the materials scheduled foruse during operation or maintenance. Ensureadequate protection for the system as well aspersonnel is provided.

Be aware that in many instances the process ofcleaning can involve potentially hazardousliquid materials requiring special handling andtreatment prior to disposal.



3.3 INSTALLATION CHECK LISTUse the following checklist for organizational and record keeping purposes. Failure to record problems withinstallation or factors required for proper installation may result in unscheduled down time.

Table 3: Installation Check List

LOCATION SHIPPING DAMAGE

Check for:❑ Adequate floor space❑ Adequate clearance above and around system❑ Level surfaces at installation site

Adequate facility connections for:❑ Exhaust❑ Electrical Hook Up❑ System Fill❑ System Drain❑ Final Rinse

Check for damage to system and describe any damage found:

If any location requirements are inadequate, please describe:

SYSTEM LEVELING

❑ Level X axis at entrance end of system cabinet❑ Levle Y axis at front of system cabinet❑ Level X axis at exit enf of system cabinet❑ Level Y axis at rear of system cabinet❑ Adjust leveling feet and re-check axis on all sides

COMPONENT INSTALLATION

Domestic Shipments Crated International Shipments

❑ Conveyor Wire Belt (for Optional Inlet Conveyor) ❑ Optional Photocell❑ Leveling Feet❑ Drain Screens❑ Optional Sump Pump System❑ Optional Treatment Interface system❑ Optional Single Add-On Dryer Module❑ Optional Dual Add-On Dryer Module❑ Pump Drain Plugs

Notes:

❑ Optional Inlet Conveyor Assembly❑ Conveyor Wire Belt (for Optional Inlet Conveyor) ❑ Optional Photocell❑ Leveling Feet❑ Drain Screens❑ Optional Sump Pump System❑ Optional Treatement Interface System❑ Optional Single Add-On Dryer Module❑ Optional Dual Add-On Dryer Module❑ Bolt on Sound Enclosure❑ Exit End Conveyor Drive Assembly❑ Pump Drain Plugs

Notes:

COMPLETE UTILITY CONNECTIONS

❑ Verify system voltage, phase, and Hz rating❑ Check electrical power connections

Check for proper:❑ Power connections❑ Water connections❑ Drain connections❑ Exhaust connections❑ Pump and Blower rotation

Aquastorm

100™ & A

quastorm 200™

Installation Manual

2-9317-520-00-0 — R

ev. 121

3.4A

QU

AS

TO

RM

200™ S

YS

TE

M

FO

OT

PR

INT

DR

AW

ING

S

Figu

re 12: Aq

uastorm

200™ Fron

t

Bag FilterDoor (Open)(Optional)

7334/7774 mm(304.5/306.1 in.)

7480/7520 mm(294.5/296.1 in.)

489(19.3)

102/127 mm(4.0/5.0 in.)

Adjustable Legs

StandardExit

ExtendedExit

(Optional)

251 mm(9.9 in.)

1185 mm(46.2 in.)

AdjustableTransitionConveyor(Optional)

842 mm(32.8 in.)

5944 mm(231.8 in.)

7400/7440 mm(291.3/292.9 in.)

7653/7693 mm(301.3/302.9 in.)

Bag FilterDoor (Open)

(Optional)

510(20.1)

43 mm(1.7 in.)

135 mm(5.3 in.)

ElectricalConnection

3 in. Conduit

DisconnectFinalRinse

432(17.0)

Dryer #1756 mm(29.8 in.)

Dryer #2752 mm(29.6 in.)

1238 mm(48.7 in.)

1056 mm(41.6 in.)

System Drain

Rinse559 mm(22.0 in.)

1156 mm(45.5 in.)

6004 mm(234.2 in.)

Frame

1054 mm(41.5 in.)

1056 mm(41.6 in.)

Wash1219 mm(48.0 in.)

Pre-Wash559 mm(22.0 in.)

ChemicalIsolation889 mm(35.0 in.)

Standard Configuration – Does not include dryer stations #3 or #4.

842 mm(33.1 in.)

Aquastorm

100™ & A

quastorm 200™

222-9317-520-00-0 —

Rev. 1

Installation Manual

Figu

re 13: Aq

uastorm

200™ Top

5325 mm(209.6 in.)

7734/7774 mm(304.5/306.1 in.)

Standard Drain

1375 mm(53.6 in.)

Blower SlideAccess Area

(Optional)

ElectricalConnection3 in. Conduit

1095 mm(42.7 in.)

Standard InletConveyor

539 mm(21.2 in.)

Electrical CabinetAccess Area

4270 mm(166.5 in.)

4390 mm(171.2 in.)

850/890(33.5/35.0)

1575 mm(61.4 in.)

632 mm(24.6 in.) 787 mm

(31.0 in.)

305 mm(11.9 in.)

Control Panel

AdjustableTransitionConveyor(Optional)

164 mm(6.5 in.)

Ø 267 mm(10.5 in.)Exhaust

Port (2 Pl)1195 mm(47.0 in.)

1820 mm(71.0 in.)

Fill Lineto Rinse

FinalRinseLine

6710/6750 mm(264.2/265.7 in.)

4085 mm(160.8 in.)

Bag FilterDoor (Optional)

3100 mm(122.0 in.)

Standard Exit

Extended Exit(Optional)

610 mm(23.8 in.)

Bulkhead to AdjustableTransition Conveyor

Bulkheadto Standard

Inlet Conveyor

Bag FilterDoor

(Optional)

CLS Drain (Optional)

1040 mm(40.9 in.)

600(23.6)Typ.

1518 mm(59.2 in.)

1903 mm(74.2 in.)Blower Slide

Access Area(Optional)

External FeedChemical

Isolation Line(Optional)

Split FillLine to Wash

(Optional)

4488 mm(175.0 in.)

4565 mm(179.7 in.)

910 mm(35.8 in.)

70 mm(2.8 in.)


80/120 mm(3.1/4.7 in.)



Figure 14: Aquastorm 200™ Side

3.5 AQUASTORM 100™ SYSTEM FOOTPRINT DRAWINGS

Figure 15: Aquastorm 100™ Side

Optional Light Status Tower

Inlet Connections

589 mm(23.01 in.)

1276 mm(49.8 in.)

20 mm(0.8 in.) 1060 mm

(41.3 in.)

105 mm(4.1 in.)

1327 mm(51.8 in.)

1537 mm(59.9 in.)Frame

Optional Light Status Tower

Inlet Connections

589 mm(23.01 in.)

1276 mm(49.8 in.)

20 mm(0.8 in.)

1060 mm(41.3 in.)

105 mm(4.1 in.)

1327 mm(51.8 in.)

1537 mm(59.9 in.)Frame

Aquastorm

100™ & A

quastorm 200™

242-9317-520-00-0 —

Rev. 1

Installation Manual

Figu

re 16: Aq

uastorm

100™ Top

4703/4743 mm(185.2/186.7 in.)

4961/5001 mm(195.3/196.9 in.)

Standard Drain

1375 mm(53.6 in.)

Blower SlideAccess Area

ElectricalConnection

3 in. Conduit

1095 mm(42.7 in.)

StandardInlet

Conveyor

539 mm(21.2 in.)

Electrical CabinetAccess Areas

2558 mm(100.7 in.)

3318 mm(130.6 in.)

850/890 mm(33.5/35.0 in.)

632 mm(24.6 in.)

1575 mm(61.4 in.)

787 mm(31.0 in.)

305 mm(11.9 in.)

Control Panel

AdjustableTransitionConveyor

164 mm(6.5 in.)

Ø 267 mm(10.5 in.)Exhaust

Port (2 Pl)

1195 mm(47.0 in.)

2350 mm(92.5 in.)

80/120 mm(3.1/4.7 in.)

Fill Line

FinalRinseLine

800 mm(31.5 in.)

2185 mm(86.0 in.)

Bag Filter Door

2310 mm(90.9 in.) Standard

Exit

OptionalExtended

Exit610 mm(23.8 in.)

Bulkhead to AdjustableTransition Conveyor

Bulkheadto Standard

Inlet Conveyor


1550 mm(61.0 in.)

Aquastorm

100™ & A

quastorm 200™

Installation Manual

2-9317-520-00-0 — R

ev. 125

Figu

re 17: Aq

uastorm

100™ Fron

t

489 mm(19.3 in.)

FinalRinse

559 mm(22.0 in.)

Dryer #1756 mm(29.8 in.)

Dryer #2752 mm(29.6 in.)

Bag FilterDoor (Open)

5393/5433 mm(212.3/213.9 in.)

5646/5666 mm(222.3/223.9 in.)

3937 mm(155.0 in.)

510 mm(20.0 in.)

102/127 mm(4.0/5.0 in.)

Adjustable Legs

1059 mm(41.3 in.)

1259 mm(49.6 in.)

3997 mm(157.4 in.)

Frame

25 mm(1.0 in.)

1238 mm(48.7 in.)

ElectricalConnection3 in. Conduit

StandardExit

Disconnect

OptionalExtended

ExitWash

1219 mm(48.0 in.)

Pre-Wash559 mm

(22.01 in.) 842 mm(33.1 in.)

135 mm(33.1 in.)

43 mm(1.7 in.)

System Drain

248 mm(9.7 in.)

1185 mm(46.2 in.)

AdjustableTransitionConveyor

842 mm(32.8 in.)

2397 mm(94.4 in.)

5473/5513 mm(215.5/217.0 in.)

5727/5767 mm(225.5/227.0 in.)







SECTION 4: EQUIPMENT AND TOOLS REQUIRED

4.1 PROTECTIVE CLOTHINGANSI (American National Standard Institute)approved items:

• Safety Glasses• Steel Toe Safety Shoes• Acid Resistant Smock• Long-Sleeved Garment• Heat Protective Gloves

4.2 TOOLS AND MATERIALS• Flat Blade Screwdriver• Phillips Head Screwdriver• Channel Lock Pliers• Pipe Wrenches

• Teflon® Tape• Schedule 80, CPVC Piping

Fill – 3/4 in.Final Rinse – 3/4 in.Drain – 1-1/2 in.

• Electrician's Pliers• Needle Nose Pliers• Wire Cutters and Strippers• Volt-Ohm Meter• Clamp Ammeter• Carpenter's Level• Allen Wrench (Hex) Set• Adjustable Wrenches 7/16 in. – 1-1/8 in.

INTERNATIONAL SHIPMENTSThe following additional tools are required:

• Pry Bars• Claw Hammers• Circular Saw (Rip Cut Blade)

4.3 EXPENDABLE ITEMS• Lint-Free Cloths• Glass Cleaner• Saponifier• Scale Stripper• Defoamer

4.4 RIGGING EQUIPMENT

DOMESTIC SHIPMENTSMinimum Two (2) Ton (4,000 lbs.) Capacity ForkLift

INTERNATIONAL SHIPMENTSMinimum Three (3) Ton (6,000 lbs.) CapacityFork Lift

4.5 MAINTENANCE• Heavy Duty Hose (3/4 in.) • Nozzle and Storage Reel






SECTION 5: SHIPPING ARRANGEMENT

Domestic shipments of the Aquastorm 200™and Aquastorm 100™ are configured withwheels for easy maneuverability. The entiresystem is wrapped in moisture absorbentpolyethylene for protection during transit.

International (overseas) shipments of theAquastorm 200™ and Aquastorm 100™ are alsowrapped in moisture absorbent polyethylene forprotection during transit. The wrapped systemis then bolted to a skid and enclosed in awooden crate to ensure safe arrival at itsdestination.



Follow the specific unpacking procedures thatapply to your shipment destination and specificsystem. This manual makes reference to boths tandard and opt iona l conf igura t ions .Disregard options that do not apply to yoursystem configuration.

Transport the Aquastorm200™ or Aquastorm 100™system crate using a fork

lift. This equipment is extremely heavy andattempting to hand lift will result in personalinjury.

It is the responsibility of the customer toprovide any r igging devices required totransport the skidded system to the site ofinstallation.

Do Not open crates priorto moving them to theirfinal site of installation or

damage may occur.

5.1 SHIPPING WEIGHTS AND DIMENSIONSAquastorm 200™ and Aquastorm 100™systems are shipped as one unit . Somestandard and opt ional components areremoved from the system prior to shipment.Refer only to installation instructions whichapply to your system configuration.

All weights and dimensions areapproximated figures and are tobe used as reference only.

AQUASTORM 200™ DOMESTIC SHIPMENT DIMENSIONSCabinet Length 684 cm (269 in.)

Cabinet Width 158 cm (62 in.)

Cabinet Height 145 cm (57 in.)

AQUASTORM 100™ DOMESTIC SHIPMENT DIMENSIONSCabinet Length 684 cm (269 in.)

Cabinet Width 158 cm (62 in.)

Cabinet Height 145 cm (57 in.)



5.2 PACKAGE CONFIGURATIONS

This manual makes reference toboth standard and optionalcon f igura t ions . D is regard

options which do not apply to your systemconfiguration.

Refer to the fo l lowing i temized l is t foridentification and location of componentsremoved from the system prior to shipment.

DOMESTIC SHIPMENTS

Figure 18: Domestic Packaging Arrangement (Aquastorm 200™ Shown)

Table 4: Domestic Shipment Packaging Arrangement

ITEMPACKAGING

ARRANGEMENT

Main Cabinet On Wheels

Optional Add-On Single Dryer Module On Wheels

Optional Add-On Dual Dryer Module On Wheels

Optional Sump Pump On Van wrapped in pads

Optional Sump Pump PlumbingRubber UnionsHose Clamps

Loose on Van

Optional Treatment Interface system On Van wrapped in pads

Roll of Conveyor Wire Belt On separate pallet

Optional Adjustable Inlet Conveyor Extension On separate pallet

Optional Roll of CheckMate Conveyor Wire Belt On separate pallet



DOCUMENTATION PACKAGEA separa te ca rdboard box l abe ledDocumentation Package Enclosed contains thefollowing items.

• System Documentation Package with:High Voltage Electrical SchematicsControl Voltage Electrical SchematicsSystem Installation DrawingInstruction ManualBill Of Materials (BOM) ManualAssembly Drawings

• Two (2) sets Wire Belt Connecting MasterLinks

• Aquastorm 200™ Systems• 12 Main Cabinet Leveling Feet • 12 Pads for Leveling Feet• Six (6) Drain Screens

• Aquastorm 100™ Systems• Eight (8) Main Cabinet Leveling Feet• Eight (8) Pads for Leveling Feet• Five (5) Drain Screens

• Four (4) Optional Single Add-On DryerModule Leveling Feet

• Set of Optional Single Add-On DryerModule Interface Hardware• 59 SST Bolts, flats, and lock washers

• Four (4) Leveling Feet for Optional SingleAdd-On Dryer Module

• Four (4) Pads for Optional Single Add-OnDryer Module Leveling Feet

• Two (2) sets Optional CheckMate ConveyorConnecting Master Links

Figure 19: Documentation Package



INTERNATIONAL SHIPMENTS

Figure 20: Crated System

Table 5: Domestic Shipment Packaging Arrangement

ITEM PACKAGING ARRANGEMENT

Main Cabinet Bolted to skid and crated

Optional Add-On Single Dryer Module Bolted to skid and crated

Optional Add-On Dual Dryer Module Bolted to skid and crated

Roll of Conveyor Wire Belt In a cardboard container strapped to skid

Optional Adjustable Inlet Conveyor Extension In a cardboard container strapped to skid

Exit End Sound Enclosure Strapped to skid on inside of crate

Optional Sump Pump Strapped to skid on inside of crate

Optional Treatment Interface system Strapped to skid on inside of crate

Optional Roll of CheckMate Conveyor Wire Belt In a cardboard container strapped to skid



DOCUMENTATION PACKAGEA separa te ca rdboard box l abe ledDocumentation Package Enclosed is strappedto the skid inside the crate and contains thefollowing items.

• System Documentation Package with:High Voltage Electrical SchematicsControl Voltage Electrical SchematicsSystem Installation DrawingInstruction ManualBill Of Materials (BOM) ManualAssembly Drawings

• Two (2) sets Wire Belt Connecting MasterLinks

• Aquastorm 200™ Systems• 12 Main Cabinet Leveling Feet • 12 Pads for Leveling Feet• Six (6) Drain Screens

• Aquastorm 100™ Systems• Eight (8) Main Cabinet Leveling Feet• Eight (8) Pads for Leveling Feet• Five (5) Drain Screens

• Four (4) Optional Single Add-On DryerModule Leveling Feet

• Set of Optional Single Add-On DryerModule Interface Hardware• 59 SST Bolts, flats, and lock washers

• Four (4) Leveling Feet for Optional SingleAdd-On Dryer Module

• Four (4) Pads for Optional Single Add-OnDryer Module Leveling Feet

• Two (2) sets Optional CheckMate ConveyorConnecting Master Links







SECTION 6: DOMESTIC UNPACKING PROCEDURES

Read this section in i ts entirety prior toperforming any unpacking procedures.

Heavy Objects — Do nota t t e m p t t o m o v e l a r g eassemblies without the use

of a fork lift or other rigging equipment. Somelarge assemblies are extremely heavy and anyattempt to lift the assembly by hand will causepersonal injury.

6.1 LOCATE AND LEVEL THE SYSTEM

Tools required for unpacking:• Minimum two (2) ton (4000 lb.) capacity

fork lifts• 1-1/2 in. adjustable or fixed wrench

Wheel the Aquastorm 200™ or Aquastorm100™ into place for installation.

To prevent loss of parts orinstallation hardware, do notremove any system components

f rom the i r con ta ine rs p r io r to the i rrequirement in the installation process.

LEVELING FEET4. Locate and open the cardboard container

labeled Documentation Package Enclosed.


5. Remove the 12 system leveling feetrequired for the Aquastorm 200™ or theeight (8) system leveling feet required forthe Aquastorm 100™ from the container.

Figure 23: Leveling Foot



6. Using a two (2) ton (4,000 lb.) minimumcapacity fork lift, carefully position theextended forks at their widest setting underthe frame of the Aquastorm 200™ orAquastorm 100™. Do not place the forks atthe CAUTION points.

7. Once the fork lift is in place, carefully raisethe system off the floor high enough toremove the wheels. Use the 1-1/2 in.adjustable or fixed wrench to remove thewheels.

8. As each wheel is removed install the 12leveling feet on the Aquastorm 200™system and the eight (8) leveling feet on theAquastorm 100™ system.

9. Install the leveling feet so they extendapproximately 12.7 cm (5 in.) from the baseof the system frame. Be consistent witheach leveling foot.

10. Remove the 12 Aquastorm 200™ or eight(8) Aquastorm 100™ pads for the levelingfeet from the cardboard container labeledDocumentation Package Enclosed. Placethe pads below where each leveling footrests on the floor at the site of installation.

11. Carefully and slowly lower the Aquastorm200™ or Aquastorm 100™ onto the pads atthe site of installation. Remove the fork lift.



6.2 CABINET LEVELING PROCEDUREFor all systems, refer to Figure 24 on page 36 toadjust and secure the level ing feet . ForAquastorm 200™ systems refer to Figure 25 onpage 37 for X and Y axis information. ForAquastorm 100™ systems refer to Figure 26 onpage 37.

Figure 24: Leveling Foot Adjustment

1. On the X axis, place a level positioned onthe underside corner of the Aquastorm200™ or Aquastorm 100™ metal frame nearthe leveling foot.

2. Make the necessary height adjustments atthe base of the leveling foot hex head.

3. Turn the leveling foot hex head clockwise toelevate the system or counterclockwise tolower the system until the distancebetween the base frame of the cabinet andthe floor is approximately 10.16 cm (4 in.).

4. Repeat the above steps for all four (4)corners of the system, front and rear.

5. On the Y axis, place the level positioned onthe underside corner of the Aquastorm200™ or Aquastorm 100™ frame near aleveling foot.

6. Make the necessary adjustments to theleveling feet to bring the system into level.

7. Recheck the X axes to be sure the levelingat these points have not changed.

8. Repeat the above steps as necessary.

10.16 cm(4.0 in.)

Leveling FootHex Head

CabinetBase



Figure 25: Aquastorm 200™ Leveling Foot Locations


X

YTop View of Aquastorm 200™

Twelve (12) Leveling Feet Locations Designated by this Symbol

Y

X

Top View of Aquastorm 100™

Eight (8) Leveling Feet Locations Designated by this Symbol



6.3 REMOVING SYSTEM PACKING MATERIALSTo ensure safe arrival to your facility, theAquastorm 200™ or Aquastorm 100™ and itscomponents are carefully padded and secured.Remove the packaging materials from thelocations outlined below.

To prevent unnecessarydamage to the cabinet'spolypropylene surfaces,

use extreme caut ion when cutt ing orremoving packaging materials so as not toscratch or cut into the polypropylenesurfaces.

1. Remove the plastic wrap from around theperimeter of the system.

Figure 27: System with Protective Plastic Wrapping (Aquastorm 200™ Shown)

2. Remove the system rear access panels toaccess the system tanks.

Figure 28: System with Rear Panels Removed (Aquastorm 100™ Shown)



3. Remove any spacers or padding and thepackaging tape securing the wash tank lid,rinse tank lid, and chemical isolation tanklid (Aquastorm 200™ systems only).

4. Reinstall the tank lids and rear accesspanels.

Figure 29: Tank Packaging

5. Remove the packaging tape securing thesound enclosure lid and tool kit door. Forinstallation information refer to 8.4. Bolt onSound Enclosure on page 56

Figure 30: Sound Enclosure Packaging

6. Remove the packaging tape and foampadding from the optional spray wand inthe sink.

Figure 31: Sink Padding

Remove Spacer

Remove Tape

Remove Tape

Remove Tape

Remove Tapeand Padding



6.4 INSTALLING DRAIN SCREENSThe Aquastorm 200™ contains six (6) drainscreens. Install them as follows:

• Two (2) in prewash section• One (1) in wash tank• One (1) in rinse tank• One (1) in optional chemical isolation tank• One (1) round screen in utility sinkThe Aquastorm 100™ contains four (4) drainscreens. Install them as follows:

• Two (2) in prewash section• One (1) in wash tank• One (1) round screen in utility sinkRefer to the illustrations below for properinstallation of the drain screens. Prewash drainscreen installation is identical for all Aquastorm100™ and Aquastorm 200™ systems.

1. Locate and open the cardboard containerlabeled Documentation Package Enclosed.


2. Locate and remove the tank drain screens.

Figure 33: Prewash and Tank Drain Screen

Install the two (2) prewash drain screens fromthe front of the prewash section.

1. Open the front window.

2. Remove the prewash splash shield.

3. Install one (1) prewash drain screen overthe prewash cascade drain (the drainclosest to the front of the system).

4. Install the second prewash drain screenover the prewash drain at the rear of thesystem.

Figure 34: Prewash Section Location

Prewash Section

Prewash Section with Window Open



Install the three (3) Aquastorm 200™ tank drainscreens and one (1) Aquastorm 100™ draintank screen from the rear of the systems.

1. Remove the rear access panels startingwith the panel closest to the entrance end.

2. Remove each of the tank covers from theirrespective tanks.

3. Install one (1) tank drain screen in thebottom of each of the tanks.

4. Replace the tank covers on each of therespective tanks.

5. Reinstall the rear access panels.

Figure 35: Aquastorm 200™ Tank Locations

Figure 36: Aquastorm 100™ Tank Location

Wash TankChemicalIsolation Tank

Rinse Tank

Exit End

EntranceEnd

Utility Sink

Wash Tank

Entrance End

ExitEnd

Utility Sink



6. Install one (1) drain screen in the optionalutility sink.

Figure 37: Utility Sink Drain Screen

6.5 PUMP DRAIN PLUGDuring cold weather months, the drain plugsfor the wash and rinse section pumps areremoved prior to shipment. This allows any fluidrema in ing ins ide the pumps to d ra incompletely and avoid freezing damage to thepumps.

Locate the two (2) drain plugs shipped withinthe documentation package. Install one (1)each in the bottom side of the wash and rinsepump.

DrainScreen



SECTION 7: INTERNATIONAL UNPACKING STEPS

Read this section in i ts entirety prior toperforming any unpacking procedures.

Heavy Objects — Donot attempt to move largeassemblies without the

use of a fork lift or other rigging equipment.Some large assemblies are extremely heavyand any attempt to lift the assembly by handwill cause personal injury.

7.1 INITIAL PREPARATION AND CRATE REMOVAL

Tools required for unpacking:• Minimum three (3) ton (6,000 lb.) capacity

fork lift• Circular Saw with rip cut blade• Pry bars• Claw hammers• Socket ratchet with

1-1/2 in. socket and 3/4 in. socket

1. Using a three (3) ton (6,000 lb.) minimumcapacity fork lift, transport the Aquastorm200™ or Aquastorm 100™ system crate tothe general vicinity of installation.

To prevent unnecessarydamage to the systemcabinet polypropylene

surfaces, use extreme caution when cuttingor removing packaging materials so as not toscratch or cut into the polypropylene surfaces.

2. Using a circular saw with a rip cut blade,adjust the blade depth to approximately 2cm (3/4 in.).

3. Refer to Figure 38 on page 43 and carefullycut an end panel of the crate. Theillustrated dotted cutting line is locatedapproximately 20 cm (8 in.) from the top ofthe crate. Numbers 1 and 3 on theillustration indicate the crate end panels.

4. Repeat Step 3. for the opposite end of thecrate.

Figure 38: Dismantle Crate

Crate End PanelCra

te S

ide P

anel

1

2

Adjust Blade DepthThen Cut on Dotted 3

4Line as Indicated

Cut Along OppositeSides and Opposite Ends



5. Adjust the depth of the circular saw bladeto maximum depth.

6. Refer to Figure 38 on page 43 and carefullycut along one (1) side panel of the crate.The illustrated dotted cutting line is locatedapproximately 20cm (8 in.) from the top ofthe crate. Numbers 2 and 4 on theillustration indicate the crate side panels.

7. Repeat Step 6. for the opposite side of thecrate. The top of the crate should now becut free.

8. Using several people or a fork lift, carefullyslide the crate top off of the lower portion ofthe crate.

To avoid any damage tothe system do not dropthe trailing edge of the

crate top onto the top of the system insidethe crate. Take the same care with anyadditional bracing when it is removed.

Figure 39: Removing Crate Top After Cutting

9. Carefully remove any additional bracingfrom the inside of the top of the crate.

10. Use pry bars and claw hammers to removethe ends of the crate from the skid.

11. Remove the sides of the crate from the skid.

To prevent moisture damage to the equipmentin transit, the entire system was wrapped inmoisture absorbent plastic.

12. Remove the moisture absorbent plasticfrom the system.

13. Cut and remove the strapping securing allcardboard containers and any optionalcomponents attached to the system skid.

14. Carefully remove all components cut free inStep 13. and place them in a safe placeclose to the site of installation. Installationprocedures for these components follow inthis manual.

D o N o t o p e n a n y c a r d b o a r dconta iners un t i l d i rec ted byinstallation procedures in this

manual.



The Aquastorm 200™ or Aquastorm 100™system comes mounted on 2 x 8 foot plankswith foam shock pads, then bolted to a woodenskid using the following bolting configurations;

• 1-8 x 3 in. bolts installed in existing levelingfoot sockets in eight (8) locations (4 in front;4 at the rear), secure 16 metal shippingplates to the underside of the systemframe.

• 1/2-13 x 8 in. bolts are then insertedthrough mounting holes in the skid,through the foam pads, through the planks,then through the mounting holes on theshipping plates, and retained with jam nutsto secure the system in place on the skid.



15. Using a 3/4 in. socket wrench and ratchet,remove the two (2) jam nuts securing eachof the 16 shipping plates in place.

16. Using a two (2) ton (4,000 lb.) minimumcapacity fork lift, carefully position theextended forks at their widest setting underthe frame of the Aquastorm 200™ orAquastorm 100™. Do not place the forks atthe CAUTION points.

17. Once the fork lift is in place, carefully raisethe system off of the skid high enough toremove the 16 shipping plates and eight (8)1-8 x 3 in. bolts securing them to the systemframe.

18. Use the 1-1/2 in. socket with ratchet toremove the 1-8 x 3 in. bolts.

7.2 INSTALLING THE SYSTEM LEVELING FEETLocate and open the cardboard containerlabeled Documentation Package Enclosed.


1. Remove the 12 system leveling feetrequired for the Aquastorm 200™ or theeight (8) system leveling feet for theAquastorm 100™ from the container.

Figure 41: Leveling Foot

2. While the Aquastorm 200™ or Aquastorm100™ system is still elevated above the skid,install the leveling feet obtained in Step 1.

3. Install the leveling feet so they extendapproximately 12.7 cm (5 in.) from the baseof the system frame. Be consistent witheach leveling foot.

4. Remove the 12 Aquastorm 200™ or eight(8) Aquastorm 100™ pads for the levelingfeet from the cardboard container labeledDocumentation Package Enclosed. Placethe pads below where each leveling footrests on the floor at the site of installation.

5. Carefully and slowly lower the Aquastorm200™ or Aquastorm 100™ onto the pads atthe site of installation. Remove the fork lift.



7.3 POSITIONING THE SYSTEMUse a forklift to carefully place the Aquastorm200™ or Aquastorm 100™ in position foroperation. Ensure the machine front and backare facing correctly for required operation.

Remove the 12 leveling feet pads for theAquastorm 200™ or eight (8) leveling feet padsfor the Aquastorm 100™ from the cardboardcontainer labeled Documentation PackageEnclosed. Place them below where each of theleveling feet will rest on the floor at the site ofinstallation.

Carefully and slowly lower the Aquastorm 200™or Aquastorm 100™ onto the pads at the site ofinstallation. Remove the fork lift.

7.4 CABINET LEVELING PROCEDUREFor all systems, refer to Figure 42 on page 46 toadjust and secure the level ing feet . ForAquastorm 200™ systems refer to Figure 43 onpage 47 for X and Y axis information. ForAquastorm 100 systems refer to Figure 44 onpage 47.

Figure 42: Leveling Foot Adjustment

1. On the X axis, place a level positioned onthe underside corner of the Aquastorm200™ or Aquastorm 100™ metal frame nearthe leveling foot.

2. Make the necessary height adjustments atthe base of the leveling foot hex head.

3. Turn the leveling foot hex head clockwise toelevate the system or counterclockwise tolower the system until the distancebetween the base frame of the cabinet andthe floor is approximately 10.16 cm (4 in.).

4. Repeat the above steps for all four (4)corners of the system, front and rear.

5. On the Y axis, place the level positioned onthe underside corner of the Aquastorm200™ or Aquastorm 100™ frame near aleveling foot.

6. Make the necessary adjustments to theleveling feet to bring the system into level.

7. Recheck the X axes to be sure the levelingat these points have not changed.

8. Repeat the above steps as necessary.

10.16 cm(4.0 in.)

Leveling FootHex Head

CabinetBase





X

YTop View of Aquastorm 200™

Twelve (12) Leveling Feet Locations Designated by this Symbol

Y

X

Top View of Aquastorm 100™

Eight (8) Leveling Feet Locations Designated by this Symbol



7.5 REMOVING SYSTEM PACKING MATERIALSTo ensure safe arrival to your facility, theAquastorm 200™ or Aquastorm 100™ and itscomponents are carefully padded and secured.Remove the packaging materials from thelocations outlined below.

To prevent unnecessarydamage to the cabinet'spolypropylene surfaces,

use extreme caut ion when cutt ing orremoving packaging materials so as not toscratch or cut into the polypropylenesurfaces.

1. Remove the plastic wrap from around theperimeter of the system.

Figure 45: System with Protective Plastic Wrapping (Aquastorm 200™ Shown)

2. Remove the foam padding from thewindows and packaging tape from thesurfaces of the cabinet.

3. If your system is configured with theoptional Inlet Conveyor, remove anystrapping and padding securing theturnbuckles to the entrance end of thecabinet. Carefully set the unsecured endsof the turnbuckles on the floor until thetime of installation of the Inlet Conveyor.

Figure 46: Remove Widow Foam Padding



4. Remove the system rear access panels toaccess the system tanks.

Figure 47: System with Rear Panels Removed (Aquastorm 100™ Shown)

5. Remove any spacers or padding and thepackaging tape securing the wash tank lid,rinse tank lid, and chemical isolation tanklid (Aquastorm 200™ systems only).

6. Reinstall the tank lids and rear accesspanels.

Figure 48: Tank Packaging

7. Remove the packaging tape securing thesound enclosure lid and tool kit door. Forinstallation information refer to “Bolt onSound Enclosure” on page 56.

Figure 49: Sound Enclosure Packaging

Remove Spacer

Remove Tape

Remove Tape

Remove Tape



8. Remove the packaging tape and foampadding from the optional spray wand inthe sink.

Figure 50: Sink Padding

7.6 INSTALLING DRAIN SCREENSThe Aquastorm 200™ contains six (6) drainscreens. Install them as follows:

• Two (2) in prewash section• One (1) in wash tank• One (1) in rinse tank• One (1) in optional chemical isolation tank• One (1) round screen in utility sinkThe Aquastorm 100™ contains four (4) drainscreens. Install them as follows:

• Two (2) in prewash section• One (1) in wash tank• One (1) round screen in utility sinkRefer to the illustrations below for properinstallation of the drain screens. Prewash drainscreen installation is identical for all Aquastorm100™ and Aquastorm 200™ systems.

1. Locate and open the cardboard containerlabeled Documentation Package Enclosed.


2. Locate and remove the prewash and tankdrain screens.

Figure 52: Prewash and Tank Drain Screen

Remove Tapeand Padding



Install the two (2) prewash drain screens fromthe front of the prewash section.

1. Open the front window.

2. Remove the prewash splash shield.

3. Install one (1) prewash drain screen overthe prewash cascade drain (the drainclosest to the front of the system),

4. Install the second prewash drain screenover the prewash drain at the rear of thesystem.

Figure 53: Prewash Section Location

Install the three (3) Aquastorm 200™ tank drainscreens and one (1) Aquastorm 100™ draintank screen from the rear of the systems.

1. Remove the rear access panels startingwith the panel closest to the entrance end.

2. Remove each of the tank covers from theirrespective tanks.

3. Install a tank drain screen in the bottom ofeach of the tanks.

4. Replace the tank covers on each of therespective tanks

5. Reinstall the rear access panels.

Figure 54: Aquastorm 200™ Tank Locations

Prewash Section

Prewash Section with Window Open

Wash TankChemicalIsolation Tank

Rinse Tank

Exit End

EntranceEnd

Utility Sink



Figure 55: Aquastorm 100™ Tank Location

6. Install one (1) round drain screen in theoptional utility sink.

Figure 56: Utility Sink Drain Screen

7.7 PUMP DRAIN PLUGDuring cold weather months, the drain plugsfor the wash and rinse section pumps areremoved prior to shipment. This allows any fluidrema in ing ins ide the pumps to d ra incompletely and avoid freezing damage to thepumps.

Locate the two (2) drain plugs shipped withinthe documentation package. Install one (1)each in the bottom side of the wash and rinsepump.

Wash Tank

Entrance End

ExitEnd

Utility Sink

DrainScreen



SECTION 8: INSTALLING OPTIONS

The following options are available for use witheither the Aquastorm 200™ or Aquastorm100™:

• Light Tower• Sump pump• Treatment interface

• Exit conveyor extension• Inlet conveyor extension• Photocell• Checkmate™ hold down conveyorDisregard options that do not apply to yoursystem configuration. It is the responsibility ofthe customer to provide any rigging devicesrequired to transport the system to the site ofinstallation.

Read this section in i ts entirety prior toperforming any option item unpacking andinstallation procedures.

Heavy Objects — Donot attempt to move largeassemblies without the

use of a fork lift or other rigging equipment.Some large assemblies are extremely heavyand any attempt to lift the assembly by handwill cause personal injury.

8.1 LIGHT TOWERThe optional Light Tower ships with installationhardware. The wiring is already in place. Priorto shipping, the status tower is unbolted,wrapped in bubble pack, and taped to the top ofthe machine.

Materials and tools required for light towerinstallation:• Phillips screwdriver

To install the light tower:1. Remove the packaging from the status

tower.

2. Access the rear, entrance end enclosure.

3. With the enclosure open, position the towerupright.

4. Insert the end of the pipe through the holein the top of the cabinet.

5. Locate the four (4) phillips head screws andinsert them into the holes in the base of thelight tower.

6. Tighten the screws securely.

7. Replace the rear entrance end enclosuredoor.

Figure 57: Light Tower

8.2 SUMP PUMPThe optional Sump Pump assembly shipsconfigured with the necessary electricalconnectors and 610 cm (20 in.) of cable. Thecustomer is responsible to supply the followingadditional plumbing;

• 1-1/2 in. CPVC drain plumbing• 1 in. facility drain plumbing

Ensure Teflon© tape is used onall threaded plumbing fittings.The Sump assembly is designed

to be posit ioned at the exi t end of al lAquastorm systems.

Materials and tools required for sump pumpinstallation:• 1-1/2 in. CPVC drain pipe maximum length

of 610 cm (20 in.) • Lengths of 1 in. facility drain pipe• Teflon© Tape• CPVC Cement and Solvent• Channel lock pliers• Pipe wrench

Waste water discharge solutionsfrom Aquastorm systems maybe regulated by local, county,

state, or federal agencies. Indiscriminatedischarge is not recommended. Contact alocal governing agency for proper permits,discharge requirements, and pretreatmentconditioning prior to operating the system.



SUMP PUMP INSTALLATION1. If your system has been configured with the

Optional Sump Pump, locate and removethe assembly from the shipment contents.

2. Position the sump pump assembly at theexit end of the system, with the drain pipefacing the exit end of the system.

3. Install a customer supplied union orcoupling at the end of the 1-1/2 in. drainplumbing at the exit end of the Aquastormsystem.

4. Install the required length of 1-1/2 in. CPVCdrain pipe [not to exceed 610 cm (20 in.)], tothe remaining end of the union or coupling.

5. Connect the opposite end of the drain pipeinstalled in Step 4. to the 1-1/2 in. NPTFfitting on the sump.

6. Connect the 1.0 in. NPTF sump outlet to thecustomer supplied 1.0 in. facility drain orfacility water treatment system.

7. Locate the cable from the sump pump withthe connector labeled PG27.

8. Plug the connector labeled PG27 into thereceptacle at the exit end of the Aquastorm200™ or Aquastorm 100™ labeled PG27.

Figure 58: Sump Pump Installation Reference Drawing

8.3 TREATMENT INTERFACE

The Optional Treatment Interface assemblyships configured with the necessary electricalconnectors and 610 cm (20 in.) of cable. Thecustomer is responsible to supply the followingadditional plumbing:

• 1-1/2 in. CPVC drain plumbing• 1 in. facility drain plumbing• 3/4 in. fill plumbing.

Ensure Teflon© tape is used onall threaded plumbing fittings.The Sump assembly is designed

to be posit ioned at the exi t end of al lAquastorm systems.

Materials and tools required for treatmentinterface installation.• 1-1/2 in. CPVC drain pipe maximum length

of 457 cm (15 in.) • Lengths of 1 in. CPVC, schedule 80 facility

drain pipe• Lengths of 3/4 in. CPVC, schedule 80 fill

pipe

• Teflon® Tape• CPVC Cement and Solvent• Channel lock pliers• Pipe wrench

Connect Sump Inlet (11/2" NPTF)to Aquastorm 200'sstandard 1 1/2" NPTM, drainat the exit end of the cabinet

1 1/2" CPVC drain from system to Sump(Customer Supplied)

Connect Sump Outlet to1.0" NPTF Facility Drain(Customer Supplied plumbing)

Sump Outlet1.0" NPTF

Sump Side View

Connect Plug #PG27 fromSump into Sump receptacle atexit end of cabinet labeledPG27

Receptacle

Install a Unionor coupling Here

ConnectorCable



Waste water discharge solutionsfrom Aquastorm systems maybe regulated by local, county,

state, or federal agencies. Indiscriminatedischarge is not recommended. Contact alocal governing agency for proper permits,discharge requirements, and pretreatmentconditioning prior to operating the system.

TREATMENT INTERFACE SYSTEM INSTALLATION1. If your system has been configured with the

Optional Treatment Interface, locate andremove the assembly from the shipmentcontents. Refer to Figure 59 on page 55 asnecessary.

2. Position the treatment interface assemblyat the exit end of the system, with the drainpipe facing the exit end of the Aquastormsystem.

3. Install a customer supplied union orcoupling at the end of the 1-1/2 in. drainplumbing at the exit end of the Aquastormsystem.

4. Install the required length of 1-1/2 in. CPVCdrain pipe to the remaining end of theunion or coupling.

5. Connect the opposite end of the drain pipeinstalled in Step 4. to the 1-1/2 in. NPTFfitting on the inlet side of the treatmentinterface.

6. Connect the 1.0 in. NPTF treatmentinterface outlet to the optional CLS 1.0 in.inlet using the customer supplied 1.0 in.plumbing. Refer to the CLS Manual ifnecessary.

7. Connect the 3/4 in. fill line from theAquastorm system to the 3/4 in. NPTFfitting on the treatment interface using thecustomer supplied 3/4 in. plumbing.

8. Connect the treatment interface 1-1/2 in.drain overflow to facility drain, or to theoptional sump pump 1-1/2 in. inlet sidedrain plumbing. This connection is for highlevel overflow only.

9. Locate the cable from the treatmentinterface with the connector labeled PG26.

10. Plug the PG26 connector into thereceptacle at the exit end of the Aquastorm200™ or Aquastorm 100™ labeled PG26.

Figure 59: Treatment Interface Installation Reference Drawing

Treatment Tank Side View

Drain Overflow1 1/2" NPTF

Inlet FromAquastorm Drain1 1/2" NPTF

Fill FromAquastorm3/4" NPTF

Outlet toCLS 1" NPTFPump

Outlet to CLS 1" NPTF

Inlet FromAquastorm Drain1 1/2" NPTF

Drain Overflow1 1/2" NPTF

System 1 1/2"Drain to OptionalSump or FacilityDrain

Install Coupling Here

Connector Cable

Receptacle

Connect Plug #PG26 from theTreatment system into the receptacleat exit end of cabinet labeled PG26



8.5 EXIT CONVEYOR EXTENSIONThe optional exit conveyor extension allows in-line, direct feed capabilities. Prior to shipment,the exit conveyor extension is removed andpacked separately in the shipping crate.

Tools required for exit conveyor extensioninstallation:• 10 mm Box Wrench• 5 mm Allen Wrench• Phillips screwdriver• Pliers

INSTALL EXIT CONVEYOR EXTENSIONRefer to the following steps and Figure 62 onpage 58 to complete the installation process.

Connect electric wires to jumper strip:1. Ensure the Bolt On Sound Enclosure

installation is complete. Refer to 8.4 Bolt onSound Enclosure on page 56.

2. Open the tool cabinet door on the front ofthe bolt on sound enclosure.

3. Use a phillips screwdriver to remove thefour (4) screws holding the electrical wirecover in place.

4. Ensure all system wires are properlyinstalled in the jumper connection strip. Besure to match cable numbers when makingconnections.

5. Replace the electrical wire cover removedin Step 3.

Figure 61: Electric Wire Jumper Strip

Install exit conveyor extension:1. Locate and open the cardboard container

labeled Documentation Package Enclosed.

2. Remove the eight (8) sets of M6 hardware.

3. Locate the exit conveyor extension from thecontents of the crate.

4. Position the exit conveyor extension at theexit end of the Aquastorm system cabinet.

5. Use an Allen wrench to tighten the M6hardware and attach the exit conveyorextension to the exit end panel inside thebolt on sound enclosure.

6. Tighten all bolts securely.

Install the motor drive chain:1. Locate the drive chain, master link set, and

chain tensioner assembly in the cardboardcontainer

2. Refer to the Detail A section of Figure 62 onpage 58. Feed the motor chain around bothsprockets. Insert and lock the master link inplace.

3. Place the chain tensioner assembly aroundthe motor chain between the two (2)sprockets.

4. Adjust the chain tensioner assembly so thedistance between the chains is less thanthe diameter of the sprockets.

5. Latch the chain tensioner assembly inplace.

Install grounding bracket:1. Locate the grounding bracket, M4, and M5

mounting hardware.

2. Refer to the Detail B section of Figure 62 onpage 58. Attach the grounding bracketfrom the exit conveyor extension to themachine.

3. Tighten the bolts securely.

4. Install the conveyor wire belt. Refer to 8.8Conveyor Wire Belt on page 61.

Bolt OnSoundEnclosure

MainPowerSwitch

MachineFront

Tool Cabinet

ElectricalJumperStrip

ElectricWireCover



Figure 62: Exit Conveyor Extension

8.6 INLET CONVEYOR EXTENSIONThe optional inlet conveyor extension allows in-line, direct feed capabilities immediatelyfollowing automatic wave soldering or reflowsoldering processes.

Tools required for inlet conveyor extensioninstallation:• 8 mm Box Wrench• 13 mm Box Wrench• 5 mm Allen Wrench

INLET CONVEYOR EXTENSION INSTALLATIONRefer to the following steps and Figure 63 onpage 59 to complete the installation process.

1. Locate and remove the mounting hardwareand the adjustable inlet conveyor extensionfrom the contents of the crate.

2. Use a 13 mm box wrench to remove thefollowing hardware from either end of theidler shaft assembly to allow removal of theidler shaft assembly and spacers:

• Hex head bolts P/N 2-9200-051-00-0• Flat washers P/N 2-9232-007-00-0• Lock washers P/N 2-9233-005-00-0

Do not to loose the Teflon®

spacers (525778-01). They needto be reinstalled in Step 5. It is

not necessary to disassemble the idler shaftassembly.

3. Carefully lift the inlet conveyor assemblyand position it at the entrance end of theAquastorm system.

Machine Exit End

Left Exit Conveyor Bracket

Right ExitConveyor Bracket

Motor

BearingBlocks

Exit ConveyorDrive Shaft

SprocketAssembly

Exit ConveyorRail

Exit ConveyorWear Strip

Exit ConveyorIdler Shaft

Rear ofMachine

Sound Enclosure

Unload EndSound Plate

MotorSupport

Motor

BearingBlock

Sprocket

ChainTensionerAssembly

MotorDriveChain

Detail A

Detail A

TorqueLimiterSprocket

B

B

View B – B

Exit ConveyorRail

Exit ConveyorWear Strip

GroundingBracket



4. Install the end of the inlet conveyor, inwhich the shaft assembly was removed,into the entrance end mounting bracket (3-0077-114-01-6). Use the vertical slottedmounting hole for installation.

5. Install one (1) spacer (525778-01) at eitherside of the inlet conveyor, between the inletconveyor and entrance end mountingbracket.

6. Reinstall the idler shaft assembly removedin Step 2.

7. Align the mounting holes, then reinstall thefollowing hardware removed in Step 2.

• Hex head bolts P/N 2-9200-051-00-0• Flat washers P/N 2-9232-007-00-0• Lock washers P/N 2-9233-005-00-0

8. Finger tighten the hex bolts at this time tohold the assembly in place. Make angleadjustments later.

9. Locate the left (512779-01) and right(512778-01) threaded height adjustmentrods and turnbuckles (512780-01).

10. Use a 1/8 in. Allen wrench and an 3/8 in.box wrench to remove the shoulder screws(2-9290-011-00-0) and hex nuts (2-9237-004-00-0) from the top ends of the left threadedadjustment rods (512779-01).

11. Align the holes in the ends of the leftthreaded adjustment rods (512779-01) withthe mounting holes in the side panels (3-0787-220-01-6) of the inlet conveyor.

12. Install the threaded height adjustment rodsand turnbuckles through the threadedadjustment rods, to the side panels of theinlet conveyor with the heads of theshoulder bolts facing out and the doublehex nuts on the inside of the inlet conveyor.

13. Tighten the hardware securely using a 1/8in. Allen wrench and a 3/8 in. box wrench.

14. Adjust the height of the Inlet ConveyorExtension to the required position byturning the turnbuckles.

15. Once the inlet conveyor height adjustmentfor the required operating position iscomplete, press the inlet conveyorassembly down to the bottom of the verticalslotted mounting hole. Use a 13 mm boxwrench to tighten the hardware previouslyfinger tightened in Step 8.


Figure 63: Inlet Conveyor Extension Installation Drawing

2-9200-051-00-0M8 x 40 SST Hex Head Bolt

2-9233-005-00-0M8 SST Split Lock Washer

2-9232-007-00-0M8 SST Flat Washer

Idler Shaft Assembly

3-0077-114-01-6Conveyor Bracket

525778-01Spacer

2-9290-011-00-08 x M6 x 20 SocketHead Shoulder Bolt

2-9237-004-00-0M5 SST Hex Nut

Idler Shaft Assembly

512780-01Left and Right Turnbuckles

512778-01Right Threaded

Height Adjust Rod

512779-01Left Threaded

Height Adjust Rod

3-0787-220-01-6Side Plate



8.7 PHOTOCELLThe optional photocell emitter and mountinghardware are removed from the inlet conveyorprior to shipment.

Tools required for photocell installation:• Phillips head screwdriver• 8 mm socket and wrench• Photocell mounting bracket P/N 523977-01• M5 hex head bolts P/N 2-9210-030-00-0• M5 lock washers P/N 2-9233-003-00-0• M5 flat washers P/N 2-9232-022-00-0• M5 hex head nut P/N 2-9237-004-00-0

PHOTOCELL INSTALLATIONRefer to the following steps and Figure 64 onpage 60 to complete photocell installation.

1. Locate the component package at theentrance end of the Aquastorm 200™ orAquastorm 100™ packing skid.

2. Remove the two (2) sets of M5 mountinghardware and photocell components.

3. Align the mounting holes of the photocellmounting bracket with the slotted holes asdepicted in the illustration below, on theright hand side of the inlet conveyor, facingthe entrance end of the system.

4. Using the M5 hardware, insert the panhead bolts with flat washers through theslotted holes on the inside of the inletconveyor through the mounting holes ofthe photocell mounting bracket.

5. Install the M5 lock and M5 flat washers onthe back side of the bolt, then secure withthe M5 hex nut.

6. Securely tighten all nuts and bolts to holdthe photocell assembly in place.

Before operating the photocell,r e v i e w a n d p e r f o r m t h ePhotocell Alignment procedure

as outlined in your Aquastorm 200™ orAquastorm 100™ Instruction Manual.


Figure 64: Photocell Installation Drawing

Detail "A"

Detail "A"

M 5 Pan Head Bolt2-9210-030-00-0 ( QTY 2)

M 5 Lock Washer2-9233-003-00-0 (QTY 2)

M 5 Flat Washer2-9232-022-00-0 (QTY 4)

M 5 Hex Nut2-9237-004-00-0 (QTY 2)

Photocell Mounting Bracket523977-01



8.8 CONVEYOR WIRE BELT

If your system is not configuredwith the Optional Inlet ConveyorExtension, the conveyor wire belt

is not removed from the system for shipment,therefore it is not necessary to perform thisprocedure.

Perform this procedure if the Aquastorm 200™or Aquastorm 100™ system ordered includesthe optional inlet conveyor extension. It isrecommended that at least two (2) peopleperform this installation.

Ensure the inlet conveyor extension option isproperly instal led prior to instal l ing theconveyor wire belt. See 8.6 Inlet ConveyorExtension on page 58. Also ensure that theoptional photocell, if ordered, is installed andproperly working prior to installing the conveyorwire belt. See 8.7 Photocell on page 60.

Tools required for conveyor wire beltinstallation:• Roll of conveyor wire belt• Wire belt master link set• Needle nose pliers• Small flat head screwdriver

CONVEYOR WIRE BELT INSTALLATIONRefer to the following steps and Figure 66 onpage 62 for conveyor wire belt installation.

1. Locate and remove the roll of conveyor wirebelt from the contents of the shipment.

2. Bring the roll of wire belt to the entranceend of the Aquastorm 200™ or Aquastorm100™ system.

3. Arrange the wire belt so the Closed End ofthe Hook Loops face toward the EXIT end ofthe Aquastorm system and the smooth sideof the wire belt faces up. Refer to Figure 65on page 61.

Figure 65: Feeding the Wire Belt

4. Manually feed the wire belt from theentrance end of the cabinet through theTOP PORTION of the conveyor to the exitend.

To pull the wire belt through thesystem, reach inside the windowport of each stage and pull the

wire belt through each section.

5. Feed the remaining portion of the wire beltthrough the bottom portion of the conveyoruntil the end of the wire belt reaches theentrance end of the system.

Open Side of LoopFacing TowardEntrance End

Closed Loop SideToward Exit End

Entrance End Exit End

Feed the Wire Belt from the top of the conveyor at the entranceend toward the exit end of the system, then around theunderside of the conveyor, toward the entrance end of theOptional Inlet Conveyor assembly.



6. Assist by pulling the wire belt from the exitend of the conveyor and by reaching insidethe window port of each stage and pullingthe wire belt through.

7. Using a 13 mm socket head wrench loosenthe bolts of the four (4) conveyor driveshafts on the inlet conveyor to provideenough slack to connect the beginning andending sections of the wire belt together.

8. Locate and open the cardboard containerlabeled Documentation Package Enclosedand remove the wire belt master links.

9. Install the master links to connect thebeginning and ending sections of the wirebelt. For details on master link installation,refer to 8.10 Wire Belt Splicing Steps onpage 64.

10. Adjust each of the four (4) conveyor driveshafts to ensure consistent tension ismaintained across the wire belt. As eachconveyor drive shaft is repositioned toensure proper tension, use a 8 mm sockethead wrench to tighten the bolts.

Figure 66: Conveyor Wire Belt Installation Drawing

8.9 CHECKMATE™ HOLD DOWN CONVEYORAt the entrance end an upper conveyor gentlylays across the top of PCBs as they travel on thelower conveyor. This conveyor setup option isdesigned for product that could normally bejostled, elevated, or even flipped during thecleaning or drying process.

Perform this procedure if the Aquastorm 200™or Aquastorm 100™ system ordered includesthe Checkmate™ hold down conveyor. It isrecommended that at least two (2) peopleperform this installation.

CHECKMATE™ HOLD DOWN CONVEYOR INSTALLATIONRefer to the following steps and Figure 67 onpage 63 for Checkmate™ wire belt installation.

1. Locate and remove the roll of Checkmate™conveyor wire belt from the contents of theshipment.

Feeding the Wire Belt

Feed the Wire Belt from the top of the conveyortoward the exit end of the system, then around

the underside of the conveyor, toward the entranceend of the optional Inlet Conveyor assembly.

Feed over Top

Pull from BottomFour (4) Adjustable Drive Shafts

Remove Wire Belt Slack

Loosen the adjustable drive shafts to provide slack forwire belt master link assembly. After installing themaster link, adjust and retighten the adjustabledrive shafts so the wire belt is not slack.



2. Bring the roll of wire belt to the entranceend of the Aquastorm 200™ or Aquastorm100™ system.

3. Arrange the wire belt so the Closed End ofthe Hook Loops face toward the EXIT end ofthe Aquastorm system and the smooth sideof the wire belt faces down. Refer to Figure65 on page 61.

The smooth side of theCheckmate™ conveyorwire belt must face down.

The smooth side of the main conveyor wiremust face up. If the two smooth sides do notface each other, damage to product canoccur.

4. Lay the wire belt on top of the conveyor beltand manually feed the Checkmate™ wirebelt from the entrance end of the cabinet tothe exit end.

To pull the wire belt through thesystem, reach inside the windowport of each stage and pull the

wire belt through each section.

5. Feed the remaining portion of the wire beltthrough the upper portion of theCheckmate™ conveyor until the end of thewire belt extends over the entrance end.

6. Bring the wire belt around to the bottom ofthe entrance end of the Checkmate™conveyor, so that it hangs approximately15.24cm (6 in.) over the end and a loop canbe made to ensure adequate slack in thewire belt.

7. Locate and open the cardboard containerlabeled Documentation Package Enclosedand remove the wire belt master links.

8. Install the master links to connect thebeginning and ending sections of the wirebelt. For details on master link installation,refer to 8.10 Wire Belt Splicing Steps onpage 64.

Figure 67: Checkmate™ Wire Belt Installation Drawing

Feeding the Optional Checkmate™ Wire Belt

Lay the wire belt, smooth side down, on top ofthe conveyor belt. Feed it toward the exit endof the system, then around to the top of the

Checkmate™ conveyor, toward the entrance end.

Connecting the Checkmate™ Wire Belt Ends

Ensure at least 15.24 cm (6 in.) of conveyorbelt is left as slack at each end of the Checkmate™

conveyor prior to installing the master link.



8.10 WIRE BELT SPLICING STEPSAfter installing the conveyor wire belt orCheckmate™ wire belt, connect the endstogether to form a continuous loop using thefollowing procedure. Also use this procedure tosplice a link into the wire belt to replace a bentor damaged link.

To install splicing links:1. Install the wire belt splicing link in a U

shape. Ensure the loop ends of the splicelinks are in the same direction as the wirebelt loops.

Figure 68: Splice Points

2. Use several plastic wire ties to loosly holdthe ends of the wire belt together afterattaching the splicing links.

Figure 69: Wire Ties Holding Wire Belt Ends

3. Once the splice links are in place. Tightenthe plastic wire ties to bring the ends of thewire belt closer together.

Figure 70: Tighten Plastic Wire Ties

4. Pull the ends of the splice links through thewire belt links and spread the splice linkens apart.

Figure 71: Detail of Links

5. Use a pair of needle nose pliers to graspone (1) end of the splicing link. Insert theloop end over the belt link being spliced.

Figure 72: Insert Loop End

When the loop end of the splicing link isproperly inserted, the loop end of the splicinglink extends below the wire belt.

SpliceIntersection Points

Pull LinksThrough the Belt

Spread LinkEnds Apart



6. Use a small flat head screwdriver.

7. Insert the screwdriver under the wire beltlink, opposite the side already looped.

8. Insert the tip of the screwdriver into thesplicing link loop and apply downwardpressure on the loop by pulling thescrewdriver up.

9. Leave the screwdriver tip inserted in thebelt linking loop.

Figure 73: Seat the Link in Place

10. Continue to apply pressure on the handle ofthe screwdriver.

11. To complete the splice, press the open endof the belt linking loop on the splicing linkonto the wire belt link where thescrewdriver was first inserted.

Figure 74: Latch the Loop to the Wire Belt

12. Repeat Step 4. through Step 11. to connectthe opposite end of the belt linking loop andany other linking loops.

13. Cut and remove plastic wire ties previouslyused to hold belt sections together.

CONNECT WIRE BELT LINKSThe following graphics, courtesy of the WireBelt Company of America provide additionalconnetion information.

Install the wire belt so the flat portion runs inthe direction indicated below. The closed end ofthe loop goes toward the direction of travel. Thelarge arrows indicate the movement of thesplicing link between steps.

Figure 75: Splicing Link Direction

Pull Up onScrewdriverHandle

InsertScrewdriverHere

ScrewdriverTip in SplicingLink Loop

ScrewdriverHandleDirection

Catch WireBelt Link Here



Figure 76: Insert Splicing Link

Limit splicing link bending to the straightpor t ions o f the s t rand ra ther than thepreformed bent areas.

Figure 77: Weave Splicing Link

Figure 78: Continue Weaving Splicing Link

Complete installation of one side of the splicinglink before continuing on to the other side.



Figure 79: Complete Weaving Splicing Link

Figure 80: Connect Loop

Figure 81: Weave and Connect Opposite Side






SECTION 9: FACILITY AND POWER CONNECTIONS

This section provides step-by-step instructionsfor connecting facility power, exhaust, andwater to the Aquastorm 200™ or Aquastorm100™ aqueous cleaning system. Perform thefollowing procedures in the order in which theyare presented. Failure to do so may result indamage to the equipment or personal injury.Read each procedure in its entirety beforeperforming any installation procedures.

This section refers to standardand optional features. Disregardreferences to any features that

are not configured with the system orderedor purchased.

9.1 FACILITY WATER HOOK-UPElectrovert recommends the customer providethe following plumbing connections near or atthe system operating site:

• Serviceable unions attached to allplumbing connections.

• Serviceable ball or gate valves installed onthe appropriate pressure lines.

• Pressure gauges on the facility side ofservice valves to monitor and verifyavailability.

WATER SUPPLY• Fill and Final Rinse water supplies must be

separate.• Fill water supply requires heated water at a

temperature between 60–71°C (140–160°F).• Final rinse water supply requires heated tap

water or treated water at a temperaturebetween 60–71°C (140–160°F).

CONNECT THE PLUMBINGRefer to the Installation Sales drawing includedin the system documentation package or to theinstal lat ion drawings referenced in 3 .4Aquastorm 200™ System Footprint Drawingson page 21 or 3.5 Aquastorm 100™ SystemFootprint Drawings on page 23.

Also refer to 2.1 Facility Requirements on page7 fo r wa te r requ i rements and sys temspecifications.

1. Connect the facility water supply to the 3/4in. NPT Male SST fill inlet pipe.

2. Connect the facility water supply to the 3/4in. NPT Male CPVC Final rinse inlet pipe oroptional CLS (Closed Loop System).

Figure 82: System to Facility Water Plumbing Connections

3/4 in. NPT MaleFinal Rinse Connection

3/4 in. NPT MaleFill Connection

Redesigned Configuration withPlumbing Exit Below Floor Panel



RINSE HOSEDuring rout ine prevent ive maintenanceprocedures it is necessary to rinse out thesystem. This requires the use of a hose andspray nozzle. Install a clean-out hose in thevicinity of the system. The clean-out hoserequires either a hot and/or cold deionized (DI)water supply to ensure that no system crosscontamination occurs.

9.2 FACILITY EXHAUST HOOK-UPRefer to the Installation Sales drawing includedwith the system documentation package orrefer to the typical installation drawing on page12 of this manual for the steps that follow.

Also refer to page 5 of this manual for Exhaustrequirements and system specifications.

Do not walk or stand onthe top of the Aquastormcabinet. Damage to the

cabinet may result. The top of the cabinet isdesigned with internal exhaust plenums andis assembled from welded polypropylene.

CONNECT THE EXHAUST1. Locate the two (2) exhaust ports at the top

of the system. Each exhaust port is 25.4 cm(10 in.) in diameter.

Systems that include an optionalthird or third and fourth dryersect ion have an addi t ional

exhaust port installed.

2. Connect the facility exhaust system to theexhaust ports as specified on page 5 of thismanual.

3. Use an Inclined Manometer to verify thestatic pressure and SCFM ratings specifiedfor each exhaust port as listed on page 5 ofthis manual.

Figure 83: Exhaust Ports (Aquastorm 200™ Shown)

Exhaust Ports25.4 cm(10 in.)



9.3 CONNECT FACILITY POWER

Turn Off facility power atthe facility breaker beforeconnecting the facility

power to the Aquastorm 200™ or Aquastorm100™. Use safety lockouts on the safetydisconnect for added protection. For specificinformation review SECTION 1: SafetyInformation on page 1 and 1.3 Lock Out-TagOut on page 3. Do not operate the system orturn on power when access panels are open,except for brief periods when power isrequired for test ing or to veri fy motorrotation. Use caution when shields, panels orcovers are removed exposing electricalterminals or wires.

It is the responsibility of the customer toprovide the necessary conduit and conduitconnectors to the 4 in. conduit fitting at the exitend of the Aquastorm 200™ or Aquastorm100™ system.

For 220 V systems the customer is responsibilityto supply, install, and connect the correctamperage disconnect for the Aquastorm 200™or Aquastorm 100™ system.

For 380 and 460 V systems the main powerenclosure houses the main power disconnectwhere power is connected.

Before connecting facilitypower to the system, usea voltmeter to verify the

i n c o m i n g p o w e r a g r e e s w i t h t h especifications indicated on the system serialtag.

Refer to page 6 in th is manual fo r theschematic reference number and voltage whichapplies to your system electrical configuration.

SYSTEM GROUNDINGThe Aquastorm 200™ and Aquastorm 100™aqueous cleaning system must be grounded inaccordance with local, state, and/or federalelectrical codes, (i.e. National Electrical CodeRev. 1996).

Ensure that the redundant ground for theimmersion heaters is connected to the groundblock which is provided inside the high voltageelectrical enclosure.

Figure 84: Grounding Connections

Main Ground Block

Immersion HeaterRedundant GroundConnection

Main Power Disconnect380 V and 460 VSystems Only

Feed Wiring fromFacility Power ConduitThrough this Opening



CONNECT SYSTEM POWER1. Attach the necessary conduit and conduit

connectors to the fitting at the exit end ofthe cabinet, from the Aquastorm system tothe facility power source.

2. Bring the facility power wiring to thesystem through the conduit, then feed thewires through the conduit into the mainpower enclosure of the Aquastorm system.

Figure 85: Serial Tag, Conduit Connector, Incoming Power Opening

3. Remove the system front access panels toallow access to the electrical enclosures.

4. Open the main power enclosure.

5. Connect the 3 phase electrical service tothe primary power terminals of the MainPower Disconnect, labeled SW-01.

6. Make all ground conductor connections atthe proper terminal strip, labeled GROUND.

Figure 86: Main Power Connections

Attach Facility Conduitand Connectors Here

Feed Facility Power WiringThrough Conduit into MainPower Enclosure

SW-01

Main PowerDisconnect

Reverse any two (2)phases and reconnect



9.4 SYSTEM ELECTRICAL CHECK

Hazardous voltage canshock, burn, or caused e a t h . U s e e x t r e m e

caution when performing voltage andamperage tests on live voltage.

Refer to the related electrical schematic and/orschematic panel layout drawing included in theDocumentation Package for the followingelectrical checks and tests.

MAIN POWER CHECKIf you are not familiar with the Aquastorm 200™o r A q u a s t o r m 1 0 0 ™ s y s t e m e l e c t r i c a lcomponents or are unsure about performingthe steps in this procedure, contact your localField Engineer listed at the front of this manual.

1. Check all voltage wire connections.

2. Before activating facility power to thesystem, use a voltmeter to verify that theincoming power supply agrees with thespecifications indicated on the SystemSerial Tag located at the exit end of thesystem.

Figure 87: System Serial Tag

3. If facility power supply agrees with thespecifications, activate the facility power tothe Aquastorm 200™ or Aquastorm 100™.

4. Check the main power voltage at theincoming power side of the maindisconnect labeled SW-01, located insidethe main power enclosure. Ensure thevoltage reading is within ±10% of thevoltage listed on the system serial tag.

If the system voltage does notmeet specified tolerance, verifythat the facility power meets the

specifications on the serial tag. Correctfacility power if necessary.

5. Refer to the system electrical schematicapplicable to your system voltageconfiguration.

6. Check each leg for proper voltage at thefollowing test points:

• L1–L2• L2–L3• L1–L3

7. If the system voltage is within specifiedtolerance, refer to the Secondary VoltageCheck on page 73. If the system voltage isnot within specified tolerance, repeat thesteps under Main Power Check on page 73.

Operating the Aquastorm200™ or Aquastorm 100™at an incorrect voltage

rating will result in damage to the equipmentand void system warranty.

SECONDARY VOLTAGE CHECK1. Turn Off power at the System Power

Disconnect.

2. Remove the system front access panels.

3. Using the access keys supplied with yoursystem, unlock and open the main powerelectrical enclosure.

4. Locate the following Circuit Breakers forthe secondary side of the Control VoltageTransformer, and turn them to the Offposition.

• CB 20• CB 21



Figure 88: Secondary Voltage Testing

5. Activate power to the Aquastorm 200™ orAquastorm 100™ system at the SystemDisconnect.

6. The secondary voltage should readbetween 110 to 120 VAC. Use a voltmeter tocheck the voltage from wire #10 on CB 20to Neutral wire #2 on the Terminal Block. ORFrom wire #11 on the Terminal Block toNeutral wire #2 on the Terminal Block.

If secondary voltage is within the specifiedtolerance, proceed to Step 7.

If the secondary voltage does not meet thespecified voltages indicated, verify that theproper vo l tage tap is connected to thesecondary side of the transformer.

7. Turn Off power at the System Disconnect.

8. Reactivate following Circuit Breakers forthe secondary side of the Control VoltageTransformer, and turn them to the Onposition.

• CB 20• CB 21

When performing amperagereadings, ensure the componentbeing tested is active and power

is present on the circuit.

9. Turn On the power at the facility powersafety disconnect.

10. Use a Clamp Ammeter to check theamperage at each of the Contactor Wiresfor the Immersion Heaters, Pumps andBlowers in the High Voltage Panel.

Secondary Power Breakers

Wire #10 21 CB

TB20 CB

Wire #11



If amperage is drawn at each test point, anddoes not exceed the maximum amperage ratingaccording to the schematic for your systemconfiguration, proceed to the next set of testpoints.

If no amperage is drawn at a test point oramperage exceeds the maximum rat ingaccording to the schematic for your systemconfiguration, contact your local ThermalSystems Service Technician, listed at the frontof this manual.

Figure 89: Sample Clamp Ammeter

Table 6: Typical 460 V System Configuration

Wash Immersion Heaters CON-1 & 2

Optional C/I Immersion Heater CON-5

Rinse Immersion Heaters CON-3 & 4

IR Dryer Radiant Heaters CON-6

Optional C/I Blower CON-11

Blower #1 CON-9

Blower #2 CON-10

Optional Sump Pump CON-12

Optional Treatment Pump CON-13

Wash Pump CON-7

Rinse Pump CON-8

NEW PHOTO?



9.5 MOTOR ROTATION CHECKAfter to the release of the Aquastorm 200™ andAquastorm 100™ Instruction Manuals theblower motor was changed to a new, auto-tensioning motor. The information in thissection covers the new auto-tension blowermotor setup and supersedes the blower motorinformation currently included in Division 4 –Maintenance in the Aquastorm 200™ orAquastorm 100™ Instruction manual.

Refer to this information when setting up a newsystem, or installing a retrofit or replacementblower motor kit.

Remove the blower motorbelt on all blower motorsprior to performing any

blower motor rotation checks. Failure to doso can cause damage to the belt. Refer to 9.6Replace Blower Belt on page 79 aftercompleteing blower motor rotation checks.

Figure 90: Blower Assembly Diagram

BLOWER MOTOR ROTATION CHECKPrior to running the Aquastorm 200™ orAquastorm 100™ the operator must remove theblower motor belt and check blower motorrotation.

Toolkit required for blower motor rotationcheck:• 3/16 in. Allen Wrench• Pry Bar• 5/16 in. Socket• 1/4 in. Socket or Standard Screwdriver

To prepare to access blower motors: 1. Press the Main Power Off Control via the

membrane keypad.

2. Turn Off the main power disconnect at theexit end of the Aquastorm system.

3. Locate the turbine blower section at therear exit end of the Aquastorm cabinet.

4. Remove the rear access panels from theblower section to allow maintenanceaccess to the turbine blowers.

Spring LoadBelt Tensioner

Blower Pulley

Head Assembly

Motor

Motor Pulley

Belt

Blower MotorPower Box

RotationMotor

DirectionArrow



Figure 91: Rear View of System with Rear Access Panels Removed (Aquastorm 100™ Shown)

To access rear blowers:For systems configured without the OptionalSlide-Out Access follow all steps except Step 3.

1. Lift and remove the air filter housing andtube to the blower motor to free the blowerassembly for movement.

2. Allow the blower manifold assembly tohang freely from the rear bulkhead.

3. Locate the M8 hardware securing the Slide-Out blower trays. Use a 13 mm open endwrench and a 13 mm socket with ratchet toremove the M8 x 50 hex head bolt, M8 nut,M8 lock and flat washers, and 3/4 in.spacers from either side of the tray closestto the rear of the machine. Proceed to Step6.

4. For systems without the Slide-Out blowertray, disconnect the blower from the systembase. Use a 7/16 in. open end wrench toloosen and remove the three (3) frontblower base plate mounting bolts (M8 x 35).

5. Loosen the fourth blower base platemounting bolt and pivot the blower to theright as far as possible to allow access tothe blower belt guard.

6. Use a 3/16 in. Allen wrench to loosen andremove the two (2) 1/4-20 x 3/4in. sockethead cap screws securing the turbineblower belt guard.

7. Use a 3/16 in. Allen wrench to loosen thetwo (2) 1/4–20 x 3/4 in. socket head capscrews securing the blower belt guard.

8. Remove the screws and the belt guard.

Figure 92: Remove Blower Belt Guard

Blower Section

Head Assembly

Motor

Blower Belt Cover

1/4-20 x 3/4 in. Socket Head Screws

3/16 in. Allen Wrench



9. To relieve tension on the belt insert a prybar behind the spring load single belttensioner and push the tensioner awayfrom the belt.

Figure 93: Release Belt Tension

10. Remove the belt.

If the belt is not removed,and the blower motorruns backwards , the

tensioner can cause the belt to jump off thepulley. This can damage the belt and/or theblower motor assembly.

11. Turn power to the system On.

Risk of Electric Shock –Electrical current usedcan kill. DO NOT TOUCH

live electr ical components inside theelectrical enclosure.

12. Observe the rotation direction of theblower motor. The blower motor shouldturn in the direction of the arrow on themotor housing.

13. If rotation is correct proceed to Step 27.

14. If rotation does not follow the direction ofthe arrow turn power to the system Off.

Figure 94: Blower Motor Rotation Arrow

15. If testing a motor on a new systemproceed to Step 17.

16. If testing a retrofit, replacement, orupgrade kit blower proceed to Step 20.

17. Ensure power to the system is Off.

For a new system, when motorrotation does not follow thedirection of the arrow, the three-

phase power source to the system may beopposite to that required to run the blowermotors.

18. Access the main power disconnect switch,SW-01, in the main electrical enclosureand disconnect and reverse the phase ofany two (2) connectors.

19. Replace and tighten all wire nuts andproceed to Step 24.



20. Ensure power to the system is Off. For aretrofit, replacement, or upgrade kitinstallation, use the 1/4 in. socket orstandard screwdriver to remove the blowermotor power box cover plate.

Figure 95: Power Box Cover Plate Removal

21. Pull the electrical wires out of the powerbox and reverse the phase of any two (2)connectors.

Figure 96: Power Box Electric Wires

22. Replace and tighten all wire nuts and re-insert all wires into the power box.

23. Replace the power box cover plate.

24. Turn power to the system On.

25. Observe the rotation direction of theblower motor is the same direction as thearrow on the motor housing.

26. If blower motor rotation is now correct,proceed to Step 27.

27. Replace the belt.

28. Replace the blower belt guard.

29. If removed, re-attach the air filter housingand tube to the blower motor.

30. Resume or begin normal system setupand operation.

9.6 REPLACE BLOWER BELTEnsure the blower belt is installed correctly. Theresult of incorrect installation includes:

• Zero force spring tension from the idler armto the belt

• Belt stress, low belt tension, and highvibration from tight side installation

• Excessive idler arm casting wear• Vibration and casting wear allow motor

pulley to come in contact with the casting• Extreme belt fatigue creates less than 1000

hour belt life expectancy• Idler pulley rubbing from vibration, low

tension, and aluminum debris cause thehard anodized coating to wear away.

Figure 97: Correct Belt Installation

Bumper(Model 100 Only)



Figure 98: Incorrect Belt Installation

A correctly installed blower belt has an averagebelt life of 5000 hours and no routine wear orrubbing is apparent on pul leys or othercomponents. Failure rate of all blowers withautomatic tensioners is 0.25%.

Correcting belt installation afterwrong belt installation does notguarantee the idler belt will not

be harmed. If an idler bearing has beenrunning backward for any length of time, asudden reversal of belt direction can causeidler bearing failure due to wrong greasechanneling or new ball tracking. Also theidler bearing will already be damaged if thereis any wear to the surface of the idler pulley.

9.7 ADDITIONAL INFORMATIONRefer to the Aquastorm 200™ or Aquastorm100™ Instruct ion Manual for operat inginstructions.

Refer to the Aquastorm 200™ or Aquastorm100™ Instruction Manual, Division 3 for Start-Up and Shut-Down procedures.

Division 4 of the Aquastorm 200™or Aquastorm100™ Instruction Manual outlines ScheduledMaintenance, Correct ive Maintenance,Troubleshooting, and Calibration procedures.

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AQUASTORM 100™ AND 200™ INSTALLATION MANUAL

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