Owners Manual for IK Specific Components Insta... · Owners Manual for IK Specific Components...

1MANUL334 REV 07

Owners Manual for IK Specific Components

Belanger, Inc. P.O. Box 5470 Northville, MI 48167-5470 Customer Service Phone (248) 374-4700 Fax (248) 380-9681 www.belangerinc.com

insta-KLEEN™ System Owners Manual

INSTA-KLEEN OWNERS MANUAL

1MANUL334 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1

Table of Contents

Belanger Incorporated Limited Warranty........................................................ 2

Operational Warning......................................................................................... 3

Introduction ....................................................................................................... 4 Important Safety Information.................................................................................................... 4 Safety Symbols and Signal Words .......................................................................................... 4 IMPORTANT Safety Information – MUST READ .................................................................... 5 Safety Warnings....................................................................................................................... 5 Before You Get Started............................................................................................................ 8 Lag Bolt Usage Guidelines .................................................................................................... 10

Specifications.................................................................................................. 12 Requirements......................................................................................................................... 12 ICC space requirements ........................................................................................................ 12

Installation ....................................................................................................... 13 Getting Started ....................................................................................................................... 13 Guide Rails............................................................................................................................. 14 Optional Above-Ground Correlator ........................................................................................ 19 Optional In-Ground Correlator ............................................................................................... 22 Optional Hydraulic Unit for In-Ground Conveyor ................................................................... 23 Positioning the Insta-KLEEN Control Center (ICC) ............................................................... 27 Placement .............................................................................................................................. 28 Electrical Enclosure Overview ............................................................................................... 29 Solution Delivery Overview .................................................................................................... 30 Utilities.................................................................................................................................... 31

System Startup................................................................................................ 34 Initial Start-up and Adjustment............................................................................................... 34

Operation ......................................................................................................... 35 Overview ................................................................................................................................ 35 insta-KLEEN Control Center (ICC) ........................................................................................ 35

Maintenance .................................................................................................... 43 General .................................................................................................................................. 43 Guide Rail .............................................................................................................................. 43 Metering Pumps..................................................................................................................... 44 ICC Parts Identification .......................................................................................................... 64 Schedule ................................................................................................................................ 68


2 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL334

Belanger Incorporated Limited Warranty LIMITED WARRANTY: Seller warrants to the original purchaser that the goods sold hereunder, which are fabricated exclusively by Seller, shall be free from defects in workmanship and material under normal use and service for a period of one year from the date of shipment. This warranty is subject to the following limitations: (1) Labor to repair or replace parts is warranted to Purchaser during normal business hours through an authorized distributor or value added reseller (VAR) of Seller, or direct with Seller, for 90 calendar days from date of invoice. Labor warranty excludes all claims for warranty on labor that are determined to be nuisance service calls, misuse, lack of operational training, neglect, improper installation, repair, alteration, act of God, or accident from third party damage. Seller reserves the sole right to make determinations on the above stated limitation. All labor and service provided beyond the expiration of the labor warranty period shall be charged to the Purchaser at the rates established by the local authorized distributor or value added reseller (VAR) or direct with Seller; (2) Defective parts will be repaired or replaced through an authorized distributor or value added reseller (VAR) of Seller, or direct with Seller. This warranty does not apply to damage resulting from accident, misuse, abuse, negligence or normal wear and tear to the depreciable parts. Purchaser agrees to submit to and assist Seller or its authorized distributor or value added reseller (VAR) in conducting in-warranty inspections of the machinery and equipment including inspection of any part claimed to be defective by the Purchaser; (3) This warranty shall be void if the factory specifications for operation and maintenance are not followed, or if other than factory authorized erection, alterations or modifications are made to any parts or equipment; (4) This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, Sodium Hydroxide and Chlorinated Solvents. The Purchaser also agrees to accept the responsibility and liability for the selection and use of any chemicals listed above; (5) This warranty shall be void for all equipment failures and premature component wear caused by the use of reclaim water in the wash process; specifically, failure of high pressure valves, high pressure pumps, nozzles and un-loader valves, (6) Seller makes no warranty, express or implied, with respect to the design or operation of any entire system, in which Seller’s goods sold hereunder are mere components. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER STATUTORY OR OTHERWISE, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE; (7) In no event shall Seller be liable for any incidental, special, consequential or exemplary damages resulting from the furnishing, performance or use of any goods or services sold pursuant hereto, whether due to a breach of contract, breach of warranty, the negligence of Seller or to otherwise; not for loss of business; inconvenience, or property damage of any kind; or for any service not expressly provided herein related to or arising from the equipment or goods sold. This limitation of liability extends to any damages resulting in any way from purchaser’s use of any engineering recommendations, sales representations, technical assistance, advice or data supplied by seller to purchaser in connection with the goods or services supplied, other than that information contained in Belanger manuals, pursuant to this acknowledgment. This limitation of liability additionally extends to any damages of whatever nature resulting in any way from the purchaser’s selection and use of any chemicals not manufactured exclusively by seller but used with the purchased goods. All warranties either express, implied, or statutory, pertaining to Seller’s machinery, parts, and equipment are fully set forth herein. This limited warranty applies to the original purchaser only and is not transferable. No addition to or modification of any of the provisions of the above stated Limited Warranty shall be binding upon the Seller, unless made in writing and signed by a duly authorized employee of Seller.

Copyright © 2000 by Belanger, Inc. All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system, except as may be expressly permitted by the 1976 Copyright Act. Revised as of 6-15-00. Belanger reserves the right to change or modify the Belanger Inc. Limited Warranty without notice.



Operational Warning Formulations containing the chemicals listed below are particularly dangerous and should not be used even at low concentrations:

• Hydrofluoric Acid

• Ammonium Bi-flouride

• Bromic Acid

• Muriatic Acid

• Sulfonic Acid

• Phosphoric Acid

• Hydrogen Cyanide

• Hydrochloric Acid

• Chlorinated Solvents Belanger, Inc., does not endorse or condone the use of chemicals that are potentially dangerous to human health, the environment or property. Belanger recognizes that it is the right and sole decision of the end user operators of our equipment as to the type and dilution ratio of the chemicals used in their facilities. We strongly recommend that the end user does not select products containing any of the chemicals listed above as an ingredient in the wash solutions. The chemicals listed above are potentially dangerous to human health, and have a detrimental, deteriorating effect on the equipment and the facility. Be advised that a portion of, or all of your warranty will be voided if you determine to use any of the chemicals listed above as an ingredient in the wash solutions in conjunction with your Belanger automatic car wash equipment:

Limitation (4), of Paragraph (8), Limited Warranty, of the Belanger Terms and Conditions of Sales describes the potential limitation of warranty due to your chemical selection:

(4) This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, and Chlorinated Solvents. The Purchaser also agrees to accept the responsibility and liability for the selection and use of any chemicals listed above;

However, should the end user decide to use formulations containing any of the above ingredients, the end user should institute a comprehensive training program and implement detailed operational parameters within their organization for the proper handling and treatment of such products to minimize the potential dangers involved. Consult your chemical supplier for assistance in establishing operational guidelines in the use of their products. MSDS (Material Safety Data Sheet) should be obtained from the chemical supplier before using any chemical formulation.

During the installation process the installer is responsible for re-tightening ALL lugs, set screws and terminals located in the electrical panels. Components may

vibrate loose during shipping.



Introduction

Important Safety Information This section introduces the hazard and safety precautions associated with installing, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task may be found. Electrical shock could occur and cause death or serious injury if these safe service procedures are not followed.

Safety Symbols and Signal Words

Alert Symbol This safety alert symbol is used in this manual and on warning labels to alert you to precautions, which must be followed to prevent potential personal safety hazards. Obey safety directives that follow this symbol to avoid possible injury or death.

Signal Words The signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions that follow must be followed to prevent death, injury or damage to the equipment.

This signal word is used to alert you to a hazard or unsafe practice which WILL RESULT IN

DEATH OR SERIOUS INJURY

This alerts you to a hazard or unsafe practice which COULD RESULT IN DEATH OR SERIOUS INJURY

This signal word designates a hazard or unsafe practice, which MAY RESULT IN MINOR INJURY

When used by it self, CAUTION designates a hazard or unsafe practice, which MAY RESULT IN PROPERTY OR EQUIPMENT DAMAGE

Before You Begin Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment.

Read the Manual Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand the procedure, call a Belanger, Inc. representative at 248-349-7010. It is imperative to your safety and the safety of others to understand the procedures before beginning work.



Introduction

IMPORTANT Safety Information – MUST READ

Safety Warnings

DISCONNECT MAIN POWER SUPPLY PRIOR TO

SERVICING OR MAINTAINING EQUIPMENT

Belanger recommends that all workers observe the OSHA (U.S. Department of Labor Occupational Safety & Health Administration) Lockout / Tagout procedure prior to performing service or maintenance on machinery and equipment. Doing so will prevent unexpected energization, startup, or release of hazardous energy while maintenance and servicing activities are being performed.

BE SURE TO OBSERVE OPERATING ENVELOPE. EQUIPMENT MAY START UNEXPECTICALLY. OVERHEAD,

ROTATING AND/OR MOVING COMPONENTS COULD RESULT IN SERIOUS INJURY OR DEATH.

BE AWARE OF FOREIGN OBJECTS IN THE AREA SURROUNDING A ROTATING PIECE OF EQUIPMENT.

OBJECTS MAY BECOME TANGLED WITH EQUIPMENT AND COULD RESULT IN SERIOUS INJURY OR DEATH.

BE AWARE OF HAZARDS ASSOCIATED WITH EQUIPMENT INSTALLED ON THE FLOOR

THAT MAY BE A TRIP HAZARD.

It is imperative to your safety and the safety of others to always follow safe work procedures.



Introduction The INSTA-KLEEN is a flexible customer configured system, designed to meet the needs of auto dealerships, fleet operators and auto rental agencies. The base system comes with a “Quad” cloth curtain for cleaning the front, top surfaces, and rear of vehicles up to 90” tall. A set of tall wheels is included to clean the front, sides and rear of the vehicles. The customer can select between a “Wash-A-Round” or a “Gyro Wrap” for the tall wheels, and can chose between cloth or “Neotex foam as a wash media. A “UNIARCH” is added to rinse the entire vehicle. The vehicle is typically driven through the wash, as opposed to being pulled through with a conveyor system. This allows the operator to control the speed of the wash and the wash quality. Slower speed results in optimum cleaning while a faster drive through can meet the needs of a quick wash during times of peek demand. The entire system is tied together and controlled with the Insta-Kleen Control Center (ICC). The ICC includes water solenoid valves, chemical pumps, motor starters, and a powerful PLC to run the entire system. These items are pre-plumbed, wired and tested for faster and less expensive installation costs. The ICC is designed with expandability to accommodate many customer-selected options. A plastic coated, steel guide rail system is included when the optional conveyor is not selected.

From the base INSTA-KLEEN, the following options can be selected. 1) Over/Under Conveyor: The Belanger conveyor is a very heavy-duty component that can now be added

to the Insta-KLEEN system. This will eliminate operator speed variation, and supply the most consistent wash quality. Studies show that system maintenance cost can be cut in half by minimizing damage caused by drivers. Three different guide rail options can be chosen for the conveyor and the standard INSTA-KLEEN guide rail is omitted.

2) Titan VPS: An optional vehicle prep system. There are 2 pumps that pump 85 GPM of reclaim water at 140 PSI to the wheels and lower sides of the vehicle. This removes heavy dirt prior to entering the curtain.

3) Presoak Arch: Includes a stainless steel UNIARCH, nozzles, check bodies, a chemical pump, and a water solenoid valve assembly pre-wired and plumbed on the ICC. A soap fan spray option can be added to apply a thick coating of presoak.

4) Wave Across: A second set of cloth mitters that oscillate from side to side for additional cleaning on the horizontal surfaces and the sides.

5) Low Side Washer: A low side washer to give added cleaning to the lower 36” of the vehicle. Available in Neotex foam or cloth, this option allows faster wash speeds when tunnel space allows for them.

6) UNIARCH: A second optional UNIARCH equipped with a stainless steel foam coated arch with brass fittings. One comes with the base system and adding a second rinse arch will also allow faster wash speeds. Many times this is connected to an optional spot free (R.O.) system when the dryer option is not selected.

7) Air Cannon Dryer: A premium Belanger dryer offering. There are 30 and 50Hp models available to meet our customer’s needs. When selected this option includes a properly sized motor starter panel, a chemical pump for drying agent (wax) and the necessary fittings. An optional dryer silencer can also be added, when noise is a problem.

8) Chemical Tire Applicator (CTA): When a tire drives over it, a strong tire/wheel-cleaning chemical is applied with an air driven pump.

9) Prep-Jet: A high-powered, 2 gun spray pressure-washer. This can be used for prepping the vehicle prior to washing, cleaning the engines, or even for washing down the bay.

10) Reclaim Systems: Offered in many sizes to meet our customer’s needs. 11) Reverse Osmosis (RO): Spot Free systems are available in several sizes, and are great for final rinse

applications. 12) Weigand™ Wash Card Systems: These units can be added to the INSTA-KLEEN system for tracking

vehicle washes and authorization. 13) IVS™ Vacuum Systems: These dual powered units are floor mounted and can be added to fulfill interior

cleaning requirements. 14) IK™ Standard Guide Rail: Guide rail system that captures the front driver-side tire of a vehicle, and

assists in proper vehicle alignment, guiding the vehicle throughout the length of the car wash. 15) IK™ Right-hand Drive Guide Rail: Guide rail system that will capture the front driver-side tire of a

vehicle in the International market, and assists in proper vehicle alignment, guiding the vehicle throughout the length of the car wash.

16) IK™ Vehicle Width Guide Rail: Guide rail system that will capture and contain the entire vehicle, and assists in proper vehicle alignment, guiding the vehicle throughout the length of the car wash.



Introduction Important: Please refer to the system drawings in this manual for space requirements and typical layouts. Refer to the supplied electrical prints for electrical requirements. Install all tunnel equipment per its corresponding component manual and your site-drawings.

This document will cover topics that are specific to the Insta-KLEEN Wash System. For information on how to install wash components, refer to their manuals, supplied electrical prints and site-specific drawings.



Introduction

Before You Get Started

Note: The Insta KLEEN Wash System is completely electrically driven.

Tools needed for installation: Chalk line 25 foot extension cord

Level Hex wrench set

Wrench set Square

Socket set Ladder

1/2” impact wrench Tape measure (50 foot or greater)

Miscellaneous hand tools Tin snips

Pry bar Hammer drill with 1/2” and 5/8” bit

Forklift (5000 lb.) Safety glasses

Work gloves

Field Purchased Supplies Needed for Installation: 3HP air compressor

DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE SERVICING ANY

EQUIPMENT!

Always wear safety glasses when performing maintenance on any equipment

It is recommended that a licensed electrician is contracted to perform all electrical installations.

A compressed Air System should be set correctly to support 90 PSI necessary to operate

equipment, but should never be set to deliver more than 120 PSI air pressure to the Belanger specified equipment.



Introduction

What to Know Before You Get Started

The Insta-KLEEN is a flexible system. It can be ordered in many configurations and with many options. Please check your order against your shipper and the equipment received. Verify that you have received all of the equipment ordered.

Note: If any items listed below are not included in your shipment, contact your supplier.

Belanger, Inc.® 1995

This manual and the accompanying equipment are

Protected by United States and International copyright and patent laws. You may make one copy of this manual. Do not make additional copies of this manual or electronically transmit it in any form whatsoever, in whole or in part, without the prior written permission of Belanger, Inc.®



Introduction

Lag Bolt Usage Guidelines



Introduction

Lag Bolt Usage Guidelines



Specifications

Requirements Utility

Electrical – Control Control Power 120VAC\60hz\1phase

Electrical – 3 phase

Base Unit: (3 motor Starter)

208VAC\60hz\3Phase\23.5Amps. 230VAC\60hz\3Phase\22.1Amps 460VAC\60hz\3Phase\10.2Amps

Deluxe Unit: (6 motor Starter)

208VAC\60hz\3Phase\41.95Amps. 230VAC\60hz\3Phase\36.5Amps 460VAC\60hz\3Phase\18.25Amps

Pneumatic 3 HP air compressor (Customer Supplied) 90 PSI minimum 120 PSI maximum

Water (fresh) (1) 1” pipe @ 18 GPM @ 40 PSI fresh water

Water (Reclaim - if applicable)

(1) 1” pipe @ 18 GPM @ 40 PSI fresh water

ICC space requirements Dimensions

Unit height 36-1/2 “

Unit width 42-1/2”

Unit depth 10”

DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE SERVICING ANY

EQUIPMENT!

Always wear safety glasses when performing maintenance on any equipment

It is recommended that a licensed electrician be contracted to perform all electrical

installations.

A compressed Air System should be set correctly to support 90 PSI necessary to operate

equipment, but should never be set to deliver more than 120 PSI air pressure to the Belanger specified equipment.



Installation

Getting Started

If you ordered and received the optional Conveyor, see the Conveyor component manual for proper layout and installation.

Note: Guide Rails are used as a reference for installing the remaining equipment. Accurate placement of the Guide Rails is required for proper positioning of all other equipment on the insta-KLEEN™ system.

Locate the Following Items Guide Rail entrance sections, 60” 2

Guide Rail center sections, 60” (Quantity will vary according to options purchased)

-

Yellow Guide Plastic (Quantity will vary according to options purchased)

10ft.

Accessory Box (Content quantities will vary according to options purchased) 3/8-16 x 1-1/4” button head bolts - 3/8-16 lock-nuts - 1/2 x 3-3/4” quick lags -

Measure the door opening at the entrance and the exit of the building. Mark the floor at the center points of each door. Run a chalk line the length of the tunnel from the center point of the entrance to the center point of the exit and snap it to create the centerline of the tunnel. This will be your reference for installing the Guide Rail.

Overhead View of Building

Ent

ranc

e

Exi

t

Place a chalk line down the center of the tunnel

Center chalk line



Installation

Guide Rails 1) Position the passenger side Y-Section at 23-1/4” from the center of the doorway to the inside

surface of the inside Guide Rail as shown below.

Note: All placement measurements are taken from the surfaces of the angle, not the plastic.

The outside (driver side) guide rail is measured from the inside surface of the inside guide rail 14-9/16”. When the plastic is put on the guide rail opening will be 13” as shown above. After installing the Y-Section, you can begin to install the center sections and exit section.

2) By using the alignment pins on the entrance end of all center sections, slide the pin into the exit end legs of the previously installed sections. Repeat until all sections are in place.

3) Once all pieces are in place, confirm that they are all properly aligned and lag them to the floor.

23-1/4”

Centerline of

Doorway

14-9/16”

13” 13”

23-1/4” 14-9/16”

Centerline of

Doorway

Left Hand Drive Right Hand Drive

48”

Centerline of

Doorway

96”

Dual Rear Tire Width

43-3/4”

Centerline of

Doorway

84”

Car Width



Installation

Guide Rails 4) After you have installed all of the Guide Rail sections, you can now install plastic sleeves. Start by

removing the Y-Sections from there lag bolts on each and set them aside.

5) Locate the two 30” plastic sleeves and slide them all the way down to the exit end of the Guide

Rails as shown below.

6) Slide the 10 foot plastic sleeves on both Guide Rails until you get close to the entrance. Once near

the entrance, re-install the Y-Section as shown below.

7) Take a measurement from the last piece of plastic to the plastic already installed on the Y-

Sections. Cut plastic to fit and install it.

Measure here on both Rails



Installation

Guide Rails

Helpful Hint

The following procedures requires field fabrication

1) Locate the supplied Guide Rail FIXTURE CLAMP (part #102941) as shown below.

2) Secure the clamp into the first hole position and drill down through the center hole on the fixture as

shown below using a 13/32 (0.406) drill bit. This will produce properly aligned holes in the plastic for the supplied 3/8-16 x 1-1/4” button-head fasteners and 3/8-16 center-lock nuts on the underside of the guide rail. Install fasteners in sequence down the rail to prevent the plastic from moving on the angle and causing hole-misalignment.

3) Repeat this process until all plastic pieces are in place and secure. Tighten the nut and bolts down

as you work your way down the conveyor. This will minimize bowing of the plastic due to temperature changes.

Note: Make sure the seams are tight as you work your way down the conveyor.

Drill down through hole here

1FSTNR-BH510: Button-Head Fastener

1NUT-CL375: Center-Lock Nut



Installation The stanchions are to be installed on the exit section of the Guide Rail at the 4 locations shown in the side image. 1) Remove the button-head screw and nut shown below. Discard the nut.

Loosen the lag bolt shown in image #2 to allow you to slightly lift the Guide Rail off of the floor. Locate the supplied support stanchion.

2) Slide the stanchion into place as in image #3 and replace the button-

head screw into the tapped hole in the stanchion (image #4). Secure the stanchion to the floor with 1/2” lags (image #5).

Image #1 Image #2

Image #3 Image #4

Image #5



Installation

Guide Rails 8) Locate and identify the four the Transition Elbows shown below and secure them on the ends of

the Guide Rails using the supplied 1-1/2” fasteners and locking nuts as shown below. The entrance elbows are mounted on an angle and the exit elbows are mounted straight.

Entrance Driver Side Entrance Passenger Side Exit Driver Side Exit Passenger Side

Exit End Elbows Entrance Driver Side Elbow

Entrance Passenger Side Elbow

9) After the Transition Elbows are installed grind the Plastic Guide Rail (plastic of the Guide Rails) to match the shape of the transition plate as shown below.

Grind here on both entrance sections to create a smooth transition onto the Y-Section



Installation

Optional Above-Ground Correlator A Correlator is used to aid the driver in properly aligning the vehicle into the Guide Rails. It uses rollers that allow the vehicle to easily move side to side and is complimented by the Belanger Y Section to ease the transition even more.

The design of the Above Ground Correlator does not require any concrete work, which means simple installation and easy maintenance for the operator. It does however require the Y-Section to be installed and removed to determine the correct placement.

The following instructs you on how to install the Belanger “Above-Ground” Correlator. You will need to use the information in this document along with you site-specific drawings for a successful installation.

Note: If there is a need to extend the Correlator and Y-section to the outside of building, locate the two 20” x 2” Y-section tube extensions. Cut to desired length. Butt the tubing up against the exit end of the rails and weld into place. If this is the case Correlators and Y-Section positions will change accordingly.

1) Locate the ten 5/16-18 x 1-1/14” fasteners, 5-16” flat washers and the ten locking nuts. Secure the ramps to the Correlator frames as shown below. The drive side requires 4 bolts and the passenger side requires 6 bolts.

Note: The Ramps should be flush with the top of the Correlator Frames.

41”

41”

31”



Installation

Optional Above-Ground Correlator 1) Assuming the Y-Section is in place, remove the six lag bolts that hold the Y-Section pieces in

place as circled below.

2) Remove the driver side entrance rail assembly.

3) Slide the Correlator into position under the passenger side Y-Section assembly. You will have to

slightly lift the Y-Section to get the Correlator into place.

4) Position the Correlator equal distance (side-to-side) between the Guide Rails and set the tunnel

depth according to the dimensions stated below.

4-1/2”

Equal Distance



Installation

Optional Above-Ground Correlator 5) Once positioned properly, locate four supplied lag bolt and secure the Correlator to the floor as

shown below.

6) Replace the driver side Y-Section assembly.

7) Locate the passenger side Correlator Frame and position it as shown below.

60”



Installation

Optional In-Ground Correlator A Correlator is used to aid the driver in properly aligning the vehicle into the Guide Rails. It uses rollers that allow the vehicle to easily move side to side and is complimented by the Belanger Y Section to ease the transition even more.

The design of the In-Ground Correlator does not allow much flexibility in the placement of the Y-Section since by this point the cement has been poured and the Correlator should already be in place. Therefore the dimensions shown in this section are of the optimum placement even though your actual placement may vary slightly due to your specific installation.

You will need to use the information in this document along with you site-specific drawings for a successful installation.

41”

41”

31”



Installation

Optional Hydraulic Unit for In-Ground Conveyor If you have purchased the optional Over-Under Conveyor, a 5HP Hydraulic Unit is included. The following is general information on the 3 available Belanger hydraulic units and specifics on the 5HP unit.

Do Not exceed 1000 PSI operating pressure on ANY systems Hydraulic Unit.

Failure to stay within limits will trip the Motor Starters.

Placement Place your Hydraulic Unit in the desired location and bolt it to the floor. Be sure it is in a safe and dry environment.



Installation

Optional In-Ground Conveyor

Hydraulic Unit Fluid Guidelines All Hydraulic Units supplied from January 2003 and earlier can use ONLY ISO 32 Premium Light Hydraulic Fluids. All new Hydraulic Units supplied after the specified dates can use both hydraulic oils or a water/glycol-based fluids. Be sure you verify which unit you have purchased by identifying the decal on the Hydraulic Reservoir. The decals are shown below.

Hydraulic ONLY Based Units Hydraulic and Water/Glycol Based Units

If you have the newer version that will accommodate either fluid type, you must select which fluid meets your needs.

• Using ISO 32 Premium Hydraulic Fluid costs less to operate and is conducive to the maximum life of all hydraulic components.

• Using Water/Glycol Fluid has the best environmental qualities such as easy cleaning of cloth or foam, cleaning up spills should a leak occur and easier maintenance of the reclaim pits.

Regardless of which fluid you are using, all systems are tested in the factory using ISO 32

Premium Light Hydraulic Fluid. Be sure to follow the appropriate Flush and Startup procedure to assure maximum life of your Hydraulic Power Unit.

If you choose a Water/Glycol Based Fluid, please select from one of the 3 recommended products listed below.

• Houghto-Safe 620 Houghton International www.houghtonintl.com 610-666-4000

• Quintolubric 702-46 Quaker Chemical Company www.quakerchem.com 610-832-4217

• Aqua-Blue Pinnacle Solutions www.pinnsol.com 877-553-5843 (Toll Free)

• CWH/LT Terrell Fluids [email protected] 800-977-8562 (Toll Free)

If you choose Hydraulic Oil, be sure to use an ISO 32 Premium Hydraulic Fluid from any manufacturer that meets the ISO 32 requirements.



Installation


Flush and Startup procedure 1) Disconnect all power to the Hydraulic Unit. 2) Fill the Hydraulic Reservoir with any of the approved fluids and fill case drain if applicable on the

10HP, 15HP and 20HP units. 3) Disconnect all devices such as hydraulic motor hoses and connect the lines together to by-pass

the motor. 4) Connect all feed lines and disconnect all return lines at the Hydraulic Unit and place in a bucket for

draining. 5) Close all flow controls and verify proper voltage and wiring. 6) Bump the Motor Starter to verify proper motor rotation. 7) Start the Hydraulic Unit and open each flow control until the fluid that comes out of the return

hoses is clean. 8) Reconnect all motors and return lines. 9) Start the Hydraulic Unit and check for proper Conveyor movement and correct rotation of all side-

wheels. 10) Adjust speeds for each component according to the individual component manuals.



Installation


5HP Hydraulic Unit The following shows the major components on the 5HP Hydraulic Unit followed by a brief description. The 5HP Hydraulic Unit is rated @ 6 GPM @ 1000 PSI with a 20 gallon steel tank.

Fluid Fill Cap

Fluid Level Sensor

Main Electrical Feed

Speed Adjustment Control (1PUMP405)

Snubber Knob

Oil temperature and level Site Gauge

(1GAUGE250)

Oil Filter

(1FILTR510)

Return Pressure Gauge 5HP Hydraulic Motor Fixed Displacement Pump

Feed Pressure Gauge Fluid Feed Manifold Fluid Return Manifold Speed Adjustment Lock

Main Pressure Adjustment

Drain Plug



Installation

Positioning the Insta-KLEEN Control Center (ICC) Since the ICC is a very important part of the insta-KLEEN™ Wash System, it is imperative to locate and install it correctly.

Although the back room is the ideal spot for the ICC, it is designed to work in the tunnel in case there is no back room in the building as long as the environment is safe from freezing temperatures.

The ICC has Solenoid Valves that must be covered to protect from dripping water

The ICC is designed to be wall mounted on either the driver side or the passenger side of the tunnel; whichever side the main utility feeds enter the building.

Traditionally the ICC is positioned first so the utility contractors can complete their duties in a timely manner.

Refer to the provided insta-KLEEN™ Wash System plan view for specific diagram and placement dimensions.



Installation

Placement The ICC houses all electrical, water, and chemical utility requirements and should be located and mounted as soon as possible to allow the contractors to get their work done.

1) Position the ICC according to your specific floor plan.

Note: The ICC as it is shipped from Belanger is not water tight and should be protected from exposure to water.

2) When it is properly positioned, square and level it. Lag the ICC to the wall.

All connections made to the ICC enclosure MUST be made through the bottom of the

enclosure. Holes are NOT pre-punched.

ICC Shown Below Has Optional Valves and Pumps



Installation

Electrical Enclosure Overview

Circuit Breakers

Motor Overloads: Standard Configuration • 1 Mitter / Gyro Wrap • 2 Side Wheels

Motor Overloads: Optional Configuration • 2 Lower Side Wheels • 2nd Mitter / Gyro Wrap

Output Board

Programmable Logic Controller (PLC)

Counter Terminal Strip

Disconnect

Zone 2 Motor Starter

Zone 1 Motor Starter



Installation

Solution Delivery Overview

Zone 1 and 2 Soap

Optional Presoak

Optional Drying Agent

Rinse Arch

Zone 2 Water / Chemical Optional Presoak

Zone 1 Water / Chemical



Installation

Utilities

Things to Know: • If your configuration consists of one set of mitters and a set of tall wheels, the mitters can be connected to “Zone

1” and the wheels can be connected to “Zone 2”. • If your configuration has Quad Wave Mitter, a Wave Across a set of tall wheels and a set of Low Side Washers,

it is recommended that you install the Quad Wave Mitter and the tall wheels on “Zone 1”, while installing the Wave Across and the Low Side Washer on “Zone 2”.

• If one Rinse Arch for RO and the Presoak option was purchased, remove the Rinse Arch Valve from the ICC (shown above) and plumb it in-line with the RO Unit and the Rinse Arch. Plumb a longer 1/2” poly-flow line from the Wax Pump to the Injector at the Tee on the Solenoid Valve

Water General Note: The water supply line should have a field-supplied ball valve shut-off.

Note: The water supply MUST be 1” diameter copper pipe @ 40 to 60 PSI.

Water (Fresh Water) 1) From the 1” main water feed install a “tee” to feed the water manifold using hose drops from

copper tube fitting to the two barbed hose fittings on the water manifold. This can be Spot Free water if no Presoak Option has been installed.

Water (Fresh and Reclaim) 1) Install one fresh water supply; 1” using a hose drop from copper tube fitting to barbed hose fitting

located to the rear of the water manifold. This can be Spot Free (RO) water if no Presoak option is installed.

2) Install one reclaim water supply, 1” using a hose drop from copper to barbed hose fitting located on the front of the water manifold. This can be Fresh water if no Reclaim is supplied.

Note: It is recommended that a licensed electrician and a professional plumber are contracted to perform all of the electrical and water installations.

If Presoak Option is installed and Spot Free water is available for rinse, the Spot Free should be plumbed directly to the Rinse Arch. 3) Connect all water lines from equipment to Solution Delivery per overview shown on the next page.

Water Manifold Assembly The water manifold assembly is part of the ICC. It comes wired from the factory but modification may need to be performed to match the system. It consists of one injection pump, three solenoid valves and a dual chambered manifold. Additional options on this assembly include drying agent, and pre-soak. It comes wired from the factory as reclaim/fresh mixed with chemical in front chamber, and fresh in back chamber of manifold.

Injection Pumps – these pumps pump exact amounts of chemical. The amount of chemical is adjustable by adjusting knobs on face of the pumps. The two adjustments are rate of stroke and stroke. Rate of stroke increases or decreases the number of strokes per second. The stroke adjustment increases or decreases the chemical volume per stroke. NEVER adjust chemical pumps unless output is on and pump is running.

Solenoid Valve – The solenoid valves are electrically controlled normally closed water valves. They open when 110VAC applied.



Installation

Utilities

3/4” Hose to Rinse Arch

3/4” Hose to Zone 2 Water/Chemical

3/4” Hose to Optional Presoak

3/4” Hose to Zone 1 Water/Chemical

1” Hose to Fresh or Reclaim Water

1” Hose Fresh or RO Water

• System comes standard with three valve assemblies

• Optional valve available for

Presoak • Injection Tee included on valve if

Drying Agent option is purchased

Optional Drying Agent

Optional Presoak

Zone 1 and 2 Soap

• System comes standard with one chemical pump

• Optional pumps available for

Drying Agent and Presoak

Injection Tee

NOTE: If one Rinse Arch for RO and the Presoak option was purchased, remove the Rinse Arch Valve from the ICC (shown above) and plumb it in-line with the RO Unit and the Rinse Arch. Plumb a longer 1/2” poly-flow line from the Wax Pump to the Injector at the Tee on the Solenoid Valve.



Installation

Utilities

Things to Know: • If your tall wheels are a set of Gyro Wraps, special wiring is required to retract the arms in case a wheel motor is

tripped. See electrical prints for details. Electrical Supply

Note: Refer to Electrical Prints for all wire connections.

A licensed electrician should install three phase power to the three phase disconnect in the ICC.

Main Disconnect

E-Stops not supplied by Belanger, Inc.

Inputs

All connections must be made through the bottom of the ICC enclosure.

E-stop

Emergency stop buttons should be located at every entry to the carwash. Contacts are to be closed when the button is pulled out and open when pressed. Wire all E-Stop buttons in series and connect them in the ICC to terminals 104 and 105.

Treadle

Install the Floor Treadle according to site specific drawings. 1) Wire switch normally open forced closed by a vehicle tire. Verify input actuation at input X1 on

PLC. Input should be OFF with no car on treadle and turn ON when actuated. Photo-eye

Install the photo-eye according to site specific drawings. 1) Place photo-eye in a location that provides a 12” offset from emitter to receiver thru the rinse arch

or just before the rinse arch. 2) Make sure that the receiver (tall mount) is located out of direct sun light. 3) Wire photo-eye receiver configured for sinking input (NPN) light operating (LO). Wire – Blue 0V,

Brown and white 24vdc, black X2 input 4) Adjust for alignment. Input should be on when photo-eye sees across bay. Input will turn off when

blocked.

Neutral for 102VAC is terminated at the terminal strip as opposed to here.

120V L1 L2 L3



System Startup

Initial Start-up and Adjustment

1) If Gyro Wrap installed, confirm the modifications shown on sheet 6 of the electrical prints have been completed.

2) Check for proper voltage on top side of Main Disconnect located in the ICC.

3) Check for 110VAC at top side of Main Disconnect Auxiliary contact and 101. Possibly check supply for GFCI tripped.

4) Pull out all E-Stops.

5) Turn on CB1 and CB2 in the ICC.

6) Switch all output modules to OFF position. Then switch zone1 and zone 2 equipment to the ON position.

7) Confirm that all equipment is ready to be run and that area is free of people and debris.

8) Shut door and turn ON Main Disconnect.

9) Observe components for proper rotation. If no motion, check remote E-Stop operation.

10) Turn OFF Main Disconnect.

11) If any components are rotating in the wrong direction, open ICC door and swap T2 and T3 wires of that component and return to step 6. Once all equipment rotating in correct direction, go to STEP 11.

12) Open ICC door.

13) Switch all output modules to OFF position.

14) Turn ON Main Disconnect.

15) Perform initial startup procedures for all components in the tunnel. Refer to individual manuals for component startup procedures (if applicable).

16) Check Photo Eye operation by confirming that the input light X2 on PLC is ON when Photo Eye not blocked. It should be OFF when Photo Eye blocked. Check both states.

17) Check Treadle operation (if treadle installed) by confirming that the input light X1 is OFF when not on the Treadle. It should be ON when vehicle is on Treadle. Check both states.

18) If Conveyer installed, check Roller count operation. Input light X3 should be ON when Conveyor trap door down. It should be OFF when trap door up from Roller coming through. Check both states.

19) If POS or wash enable device used, check WASH ENABLE for proper operation – input X0 should be OFF when system at rest. It should be pulsed ON once to enable one vehicle. If wash enable devise not used X0 should be tied to 0VDC.

20) Check Roller-Up operation (if conveyer installed and is ready for operation). To do so, turn Roller-up output ON and confirm Roller gate lifts. Turn Roller-Up output OFF and confirm that gate lowers. Then repeat while Conveyer is running and confirm that Rollers surface correctly. Switch output to AUTO position when done.

21) Prime each pump with appropriate chemical by turning corresponding ICC pump switch to the ON position. Rotate and set stroke rate (small knob on the pump) and stroke length (large knob on the pump) to 100%. Close priming valve when fluid reaches pump.

22) Adjust pumps to desired titration and dilution ratios (NEVER ADJUST WHILE PUMPS ARE OFF).

23) Run test vehicles and fine tune ICC settings and adjust equipment.



Operation

Overview The insta-KLEEN is a drive through or conveyer fleet system. This equipment in this system is electric driven not hydraulic except conveyer itself. It washes every vehicle without package or option variations for fleet efficiency. It accommodates different cars drive through speeds because it doesn’t track the cars position in the conventional manner. The system utilizes two sensing devices to initiate, track, and reset washes as vehicles passes through. The wash could also be initiated by a POS device.

insta-KLEEN Control Center (ICC)

Component Overview The ICC consists of the electrical enclosure, mounting frame, and water manifold assembly. It is a cost affective fleet controller that uses time delays to save water and chemical. The system is equipped with a user interface that allows the wash to be tweaked in for better chem./water savings and change the loading style. It’s provided with solid state, individual output modules. Each output module has its own fuse and 3 position switch for ON/OFF/AUTO. This system can control two zones of equipment, conveyor, Pre-soak arch, Rinse/wax arch, extra function, dryers, and Titans.

Electrical Enclosure The electrical enclosure houses the wash controls and motor starters for electric drive equipment. All items inside this cabinet are to be serviced by a licensed electrician.

Operator Interface The operator interface is mounted into the face of the controller. It can be used to change two types of settings D and M. D is a numerical value setting that can be adjusted up or down using + and – keys. The unit of D is quantity or seconds. M is an ON/OFF setting used to enable or disable a function.

Screen navigation

ESC key – pressing the ESC key toggles screen between D setting screen and M setting screen.

D Setting Screen – This screen is used to change/display the settings of D140 to D155.

To navigate to among D140 to D155 press the OK key until data setting is not flashing then use + and – keys to navigate.

To change data press OK key until data setting is flashing then use + and – keys to increment or decrement data set point.



Operation


Operator Interface Data Register

• D140 Front Roller count

• D141 Rear Roller count

• D142 Conveyor off delay

• D143 Titan run time

• D144 Titan delay on

• D145 Pre-soak run time

• D146 Pre-soak delay on

• D147 Zone 1 water off delay

• D148 Zone 2 water on delay

• D149 Dryer off delay

• D150 Extra-function off delay

• D151 NOT USED

• D152 NOT USED

• D153 NOT USED

• D154 Program Version

• D155 Displays number of washed vehicles

M Setting Screen

This screen used to change/display the setting of M500 to M509

To navigate among M500 to M509 press the OK key to get underline cursor flashing. Once cursor is flashing use + and – keys to navigate from M500 to M509.

To change setting navigate to M bit that you wish to change then press OK key to toggle ON/OFF. _ represents off and represents on.



Operation


Operator Interface M Bits

• M500 ON = Rear push no treadle • M505 ON = Increase Rinse/Wax photo delays

• M501 ON = Auto Roller enable • M506 NOT USED

• M502 ON = Dryer with wash • M507 NOT USED

• M503 ON = Photo-rinse direct • M508 NOT USED

• M504 NOT USED • M509 NOT USED

Inputs

The inputs are on when terminal is driven to 0Vdc (sinking). When the input is on corresponding light on controller will be on.

INPUT X0 Wash Enable – This input must be pulsed or held on to use wash. If not used it must be jumped out to 0Vdc. If pulsed on and back off the system will load only one car. When pulse on and Auto Roller enabled system will automatically give Rollers.

Typically this input is used by a POS system such as a wash card device.

INPUT X1 Treadle – This input must be off when vehicle not present. The input pulses on, then back off again when a tire runs over the treadle. Not used if rear tire no treadle selected.

INPUT X2 Rinse/Wax Photo – This input must be on when vehicle not present. The input will turn off when vehicle breaks photo beam.

INPUT X3 Roller Count (used only with conveyors) – This input must be on when not in use. The input pulses off then back on again when Roller lifts trap door.

INPUT X4 Roller Recall (front tire pull only) – This input must be off when not in use. The input turns on when Roller call button pressed. This input can only be used for calling another Roller if front tire didn’t catch first Roller. This is not a hot Roller input. INPUT X5 Extra Function Photo – The input must be on when vehicle not present. The input will turn off when vehicle breaks photo beam. Used to turn on added equipment between treadle and rinse photo eye. Use a light operated photo eye to operate this input. Input may be tied to X2 if controlling additional rinse arch installed immediately after arch controlled by rinse photo eye (Optional and not part of product offering)

INPUT X6 Load Photo – Input provided by Belanger for custom systems that DON’T HAVE A CONVEYOR. The input must be on when vehicle not present. The input will turn off when vehicle breaks photo beam. (Optional and not part of product offering). System will load a car into wash when the beam broke for .6 seconds. Will not be able to load another car until beam remade for .6 seconds. Treadle must be removed when this input used. When used make sure M500 and M501 are off, also set D140 and D141 to zero. No terminal provided, it must be wired directly to the PLC X6.

INPUT X7 Hyd/Air Low-Level –Input must be on for Output 01 to function in “AUTO”.



Operation


Operator Interface Outputs

The outputs are 110VAC solid state up to 4 amps. Each output has its own fuse and module. The lights on controller and on output module will light up when output is on. Make sure switches are in Auto position to operate wash.

OUTPUT O0: Roller-Up – Turns on when controller calls for Roller. Output will stay on until user selected number of Rollers is counted. Activates solenoid on roller up air panel to raise conveyor Roller ramp.

OUTPUT O1: Conveyor – The output turns on when controller is calling for conveyor on. Output will remain on until user selectable time has expired after wash no longer needs conveyor. Activates motor starter in panel for conveyor hydraulic unit. NOTE: This Output will not function in “AUTO” unless Input X7 is on. OUTPUT O2: Titan – Output will come on a user selectable number of seconds after treadle signal. Once on it will remain on for a user selectable period of time.

OUTPUT O3: Pre-Soak – Output will come on a user selectable number of seconds after treadle signal. Once on it will remain on for a user selectable period of time.

OUTPUT O4: Zone 1 Equipment – Will be on as soon as vehicle runs over treadle. Will remain on as long as any vehicles are between treadle and photo-eye. Will turn off after 5 seconds when no vehicle’s present.

OUTPUT O5: Zone 1 Water – Will come on when Pre-soak comes on. Will turn off if car is user selectable number of seconds into the photo-eyes or it is through photo-eyes if it’s the last car in wash. Will turn off for same conditions, if two cars in wash, but second car has not yet turned on pre-soak. Output wont turn off if >=3 cars is in wash.

OUTPUT O6: Zone 2 Equipment – Will come on 3 second after Zone 1 equipment comes on. Will turn off at same time as Zone 1 equipment.

OUTPUT O7: Zone 2 Water – Will come on a user selectable number of seconds after treadle signal. Will turn off if car is through photo-eye and it is the last car in wash. Will turn off for same condition if two cars in wash but second car has not yet turned its Zone 2 water on. Output won’t turn off if >=3 cars is in wash. If system does not have Zone 2 use this valve to distribute solution to exit most equipment in tunnel.

OUTPUT O10: Zone 1 & 2 Soap – Will come on if either Zone 1 or Zone 2 water is on. Output may also be used to pressurize reclaim water for Zone 1 and 2 if necessary.

OUTPUT O11: Rinse/Wax Arch – Will come on if one or more cars are in wash and one of them is blocking the rinse arch photo-eye.

OUTPUT O12: Dryer – If M502 = OFF the dryer will come on when a vehicle is in wash and it breaks the rinse/wax photo-eye. Dryer will turn off a user selectable number of seconds after the vehicle is through the photo-eye. If M502= ON the dryer will be on whenever a vehicle is in the wash. Dryer will turn off a user selectable number of seconds after wash is clear of vehicles. Set to on if dryers not winding up before car gets through a short tunnel.

OUTPUT O13: Extra Function – this output will turn on when input X5 is off. It will turn off a user selectable number of seconds after input is back on. Intended to control equipment before rinse/wax photo except when X2 tied to X5 and this equipment is immediately after rinse/wax arch.



Operation


Operator Interface Data Settings D140 (FRONT ROLLER COUNT) - This is the number of Rollers that will come up when front Rollers called for. Set to 0 to not call for Rollers on front tire (Range: 0 – 3).

D141 (BACK ROLLER COUNT) - This is the number of Rollers that will come up when back Rollers called for. Set to 0 to not call for Rollers on rear tire (Range: 0 – 3).

D142 (CONVEYOR OFF DELAY) - This is the number of seconds that the conveyor will remain on after wash is clear of cars and dryer is off (Range: 1 – 600).

D143 (TITAN RUN TIME) - This is the number of seconds that the Titan will run for after each vehicle instructs function to run. 180 seconds minimum increases pump and motor life (Range: 20 – 600).

D144 (TITAN DELAY ON) - This is the delay in second before the Titan function will be instructed to run after vehicle enters wash (Range: 1 – 30).

D145 (PRE-SOAK RUN TIME) - This is the number of seconds that the pre-soak will run for after each vehicle instructs function to run (Range: 15 – 120).

D146 (PRE-SOAK DELAY ON) - This is the delay in second before the pre-soak function will be instructed to run after vehicle enters wash (Range: 0 – 30).

D147 (ZONE 1 WATER OFF DELAY) - This is the number of second after vehicle enters photo-eyes that zone 1 water will turn off. Water will only turn off if vehicle breaking photo-eyes is last vehicle in wash or vehicle behind it has not yet turned on its pre-soak. Zone 1 water will never turn off if three or more vehicles are in wash. A vehicle is considered out of wash when its through rinse arch photo eyes (Range: 1 – 60).

D148 (ZONE 2 WATER ON DELAY) - This is the delay in second before the Zone 2 water function will be instructed to run after vehicle enters wash (Range: 1 – 66).

D149 (DRYER OFF DELAY) – This is the amount of time after a vehicle is through the photo-eyes that the dryer will remain on. Set value larger for simulated look back (Range: 20 – 300).

D150 (EXTRA FUNCTION OFF DELAY) - Extra function output will remain on this amount of seconds after X5 turns back on (no fixed range).

M Bits Settings M500 (REAR PUSH NO TREADLE) - Toggle on to operate wash as rear tire push no treadle. When ON you can get rear Rollers automatically when wash enable pulsed.

M501 (AUTO ROLLER ENABLED) - Toggle on to receive Rollers automatically when wash enable pulsed on.

M502 (Dryer With Wash) – Toggle on to have dryer turn on whenever a vehicle present in wash. This allows greater wind up time for shorter tunnels.

M503 (Photo Rinse Direct) – Toggle on to have rinse/wax output on whenever photo-eye is broke. This is not recommended for normal operation, it’s intended to be used instead of forcing on rinse if experiencing problems with treadle.

M505 (Increase Photo Delays) –Increases the delays for Rinse/Wax photo. Broke for delay then made for delay to be considered a vehicle.

Miscellaneous SYSTEM TIME OUT – If No change in signal from both the treadle or the photo-eye for 120 seconds the system will remove cars from wash and the equipment will begin to turn off. This time is reduced to 60 seconds if a car loads without treadle seeing back tire.



Operation


Sample Loading Configurations Conveyorized Systems

SYSTEM 1: This system has POS (wash card, button, etc) that is positioned at window when car is on conveyor with back tires past Roller-Up position. This system does not have a treadle because wash is initiated from POS.

Relevant Setting: M500 = ON – this enables rear tire push without Treadle

M501 = ON – this makes the wash initiate from POS

D140 = 0

D141 = 2 – gives 2 Rollers when wash initiated

Rear tire push no treadle (M500) – prevents the system from looking for treadle input and makes the number of Rollers on initiation equal to back Roller count.

Auto Roller (M501) – makes the wash initiate as soon as enable input is pulsed and calls for Rollers. SYSTEM 2: This system has POS (wash card, button, etc) that is positioned at window when car has front tire only past Roller-Up position. This system has a treadle but uses it for back tire only.

Relevant Setting: M500 = OFF


D140 = 1 – gives 1 Roller when wash initiated

D141 = 2 – gives 2 Rollers after rear tire goes over Treadle

Auto Roller (M501) – makes the wash initiate as soon as enable input is pulsed and calls for Rollers.



Operation


Conveyorized Systems SYSTEM 3: This system has POS (wash card, button, etc.) that is positioned before vehicle gets on conveyor. This system has treadle that is used for both tires. This system is front tire pull and vehicle should be put in neutral after front tire drives over treadle.


M501 = OFF

D140 = 1 – gives 1 Roller after front tire goes over Treadle


SYSTEM 4: This system has POS (wash card, button, ets) that is positioned before vehicle gets on conveyor. This system has treadle that is used for both tires. This system is rear tire push and vehicle should be put in neutral after back tire drives over treadle.


M501 = OFF

D140 = 0 – wash initiation only when front tire over Treadle


You may need to increase pre-soak on delay for better operation. This style is possible but system 1 is preferred instead. SYSTEM 5: This system does not have POS, wash is enabled at all times. This system has treadle that is used for both tires. This system is front tire pull and vehicle should be put in neutral after front tire drives over treadle.


M501 = OFF

D140 = 1 – gives 1 Roller after front tire goes over Treadle


You will need to jump input X0 to 0V (on state) for this wash to work. SYSTEM 6: This system does not have POS, wash is enabled at all times. This system has treadle that is used for both tires. This system is rear tire push and vehicle should be put in neutral after back tire drives over treadle.


M501 = OFF

D140 = 0 – wash initiation only when front tire over Treadle


You may need to increase pre-soak on delay for better operation. This style is possible but system 1 is preferred instead if its possible to get users to push a button to initiate wash.

You will need to jump input X0 to 0V (on state) for this wash to work.



Operation


Non-Conveyorized Systems SYSTEM 7: This system has POS (wash card, button, etc) that is positioned at vehicle window when it’s about to enter wash This system does not have a treadle because wash is initiated from POS.

Relevant Setting: M500 = ON – this enables rear tire push without Treadle


D140 = 0

D141 = 0

Rear tire push no treadle (M500) – prevents the system from looking for treadle.

Auto Roller (M501) – makes the wash initiate as soon as enable input is pulsed SYSTEM 8: This system has POS (wash card, button, etc) that is positioned at vehicle window before front tire gets to treadle.


M501 = OFF

D140 = 0

D141 = 0

SYSTEM 9: This system does not have POS, wash is enabled at all times. This system has treadle that is used for both tires.


M501 = OFF

D140 = 0

D141 = 0

You will need to jump input X0 to 0V (on state) for this wash to work.



Maintenance

General • Keeping in mind that the insta-KLEEN™ Wash System can be attended or unattended, and

there may not be a “Car Wash Expert” on site, the intention here is to highlight potential areas of preventative maintenance and to cover some of the more day to day type of adjustments.

• The car wash manager on site may determine that he/she is capable of all items. capable of some items, or not capable of any of the items. However, even if the latter is true, an awareness of these items is crucial to success. Being able to recognize problems and solve them, or to communicate them to a “Car Wash Expert” will greatly decrease down time.

• The most critical item in the day to day maintenance is a daily inspection to insure that all of the system is operating correctly. As simple as this may sound, unless the previous operational descriptions are read, and thoroughly understood, this cannot be overstated, and has direct implications on vehicle damage, and expensive equipment repairs.

• One should look for equipment malfunction, entangled debris, clogged nozzles, low chemicals, etc. These items are broken down and elaborated on in the following sections.

• To keep the machinery clean, nightly wash downs are recommended. Weekly cleaning of the aluminum frames should also be done.

• One of the best cleaning methods that has been found is to use a bronze wool pad with a citrus base cleaner. However, a Brillo™ or S.O.S.™ scrubbing pad can also be used. Rinse thoroughly. Not only does it clean the surface, but is it also polishes the aluminum as well. See Maintenance Schedule.

• Inspect utilities for leaks periodically. Leaks can be costly.

• The last two pages of this section are two identical pages of a basic Maintenance Schedule. One is laminated so that it can be taken into the tunnel with out worrying about moisture. The other is to remain in this book as a back up. Also, in the following paragraphs there is a breakdown of preventative maintenance and basic Adjustments (where applicable) for each machine.

Guide Rail Maintenance See Maintenance Schedule

Adjustments None



Maintenance

Metering Pumps

1PUMP700 (Concentrate Pump), 1PUMP725 (Non-Concentrate Pump



Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

Metering Pumps




Maintenance

ICC Parts Identification

ICC Panel Motor Starter Configurations

Part Number Motor Overloads Included 102824 3 102825 4 102826 5 102827 6

Fluid Manifold Assembly: Part #102828

• Total number of Motor Overloads included is determined by system configuration

Optional (Not Included)



Maintenance


Electrical Panel Components

Call Belanger for a programmed PLC

1ELECT-RL905 (12) 1ELECT-FS009

1ELECT-DS150

1ELECT-MS045

1SPACR140 (4) 1ELECT-CR650

1ELECT-FS955 (31)

1ELECT-FS942

1ELECT-RL942 (4)

1ELECT-MS005

1ELECT-MS008

1ELECT-MO121 (2)

1ELECT-MS017

1ELECT-MO140

1ELECT-FS959

1ELECT-DS155 (3) 1ELECT-DS156 (3)

1ELECT-RL850

1ELECT-FS002

1CNTRL135

Motor Overload part numbers vary. See Electrical Prints



Maintenance


Solution Delivery Components

1FTTNG-BH335 (4)

1TEE-BR690 (2)

1VALVE-WA180 (3)

1VALVE-WA276 (4)

1VALVE-WA252 (4)

1PLUG-BR380 (4)

1PLUG-BR690 (3) 1REDUC-BR300

PUMP105264 (3)

1ALMNM-AN108 (3)

1FTTNG-BH500 (2)

3944

1ELECT-DN500 (4)

1MCONC-BR745 (4)



Maintenance


Valve Assemblies

102147

102146



Maintenance

Schedule

Floor Treadle Switch

Item Description Weekly Monthly Yearly Check mechanical operation and limit switch adjustment as needed

X

Wash Equipment

Item Description Weekly Monthly Yearly Check and clean spray nozzles X

Check for proper distribution of soap X

Check cloth for wear and replace when needed X

Check fluid level in gear box X

Change fluid in gear box X

Check arms for smooth movement X

Grease shaft bearings (4) X

Grease pivot bearings (4) X

Check wear of Hitch Hiker disc X

Check wear of isolation mount springs and bushings X

UNIARCH

Item Description Weekly Monthly Yearly Check and clean spray nozzles X

Check for proper distribution of wax X

The procedures stated above a generic maintenance items. See the individual manuals for specific and more detailed maintenance requirements.

Insta-KLEEN™ Owners Manual 1MANUL334

Belanger, Inc. * P.O. Box 5470 * Northville, MI 48167-5470 Customer Service Phone (248) 347-4700 * Fax (248) 380-9681

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