ENVIRONMENTALIST II-B INSTALLATION MANUAL Work Order #

Transcription

1 ENVIRONMENTALIST II-B INSTALLATION MANUAL

2 The Finest Vehicle Wash Systems Page ii

3 : Page iii

4 THIS MANUAL CONTAINS INSTRUCTIONS FOR INSTALLING A RYKO ENVIRONMENTALIST II-B (EV II-B) IN A NEW OR EXISTING BAY. EQUIPMENT DISCUSSED IN THIS MANUAL COMPLIES WITH DIRECTIVES OF EC (EUROPEAN COMMUNITIES). ATTENTION! SAFE WORKING CONDITIONS AND PRINCIPLES MUST BE CONSIDERED PREVIOUS TO UNLOADING THIS EQUIPMENT AND CARRIED OUT DURING ALL PHASES OF ITS ASSEMBLY AND INSTALLATION. READ AND ADHERE TO ALL CAUTION, WARNING AND SAFETY NOTES AND PROCEDURES GIVEN IN THIS MANUAL. RYKO MANUFACTURING COULD NOT POSSIBLY KNOW, EVALUATE, AND ADVISE THE SERVICE TRADE OF ALL CONCEIVABLE WAYS THAT SERVICE MAY BE PERFORMED OR OF THE POSSIBLE HAZARDS OF EACH. ACCORDINGLY, IF USING A SERVICE PROCEDURE THAT IS NOT RECOMMENDED IN THIS PUBLICATION, BE CERTAIN THAT NEITHER PERSONAL NOR VEHICLE SAFETY IS JEOPARDIZED BY THE SERVICE METHODS SELECTED. RYKO RECOMMENDS THAT A QUALIFIED RYKO TECHNICIAN PERFORM ALL INSTALLATION AND SERVICE MAINTENANCE OF THIS EQUIPMENT. INSTALLATION OR SERVICE MAINTENANCE OF THIS EQUIPMENT BY ANY PARTIES NOT VERSED IN ITS INSTALLATION, MAINTENANCE AND OPERATION COULD VOID THE WARRANTY. STUDY ALL SPECIFICATIONS AND REQUIREMENTS CAREFULLY BEFORE PROCEEDING WITH INSTALLATION OF THE WASH MACHINE AND ANY ASSOCIATED EQUIPMENT. PAY PARTICULAR ATTENTION TO THE SECTION ENTITLED "FOR YOUR SAFETY" AND TO ALL "CAUTION", "WARNING" AND "IMPORTANT" NOTES THROUGHOUT THE MANUAL. Page iv

5 CONTENTS GENERAL INFORMATION... 1 FOR YOUR SAFETY... 1 BASIC REQUIREMENTS AND SPECIFICATIONS... 2 Air... 2 WATER... 2 ELECTRIC... 2 PHYSICAL SPECIFICATIONS... 2 specifications: parts/options... 3 CHLORINATOR:... 3 See Terms and Definitions and EV II-B Adjustment Instructions and Chlorinator System Option in the Service Manual UNDERWRITERS LABORATORIES LISTING... 3 INSTALLATION... 4 RECOMMENDED UNLOADING PROCEDURES... 4 INSTALLATION REQUIREMENTS... 4 Other Areas of EV II-B Installation... 5 INSTALLATION... 6 Installed EV II-B... 6 ASSEMBLY AND INSTALLATION PROCEDURES... 7 U.S. / METRIC CONVERSION INFORMATION... 8 INSTALLATION TOOL CHECK LIST DRAWINGS Note: Drawings, as they pertain to retrofit installations are included in shipment of retrofit kits. Typical Single Bay Layout w/ev II-B Auto-Recirculation EV II-B Installation Installation Start-Up Test Procedure Page v

6 GENERAL INFORMATION FOR YOUR SAFETY Operators should insist that the following safety instructions, as well as all other instructions listed throughout this manual be read and adhered to by all personnel installing, maintaining, operating or servicing this equipment. When installing RYKO equipment, the installation must comply with local, state, and national building codes. If in question, consult local building code authorities for additional information. The bay should be kept clean at all times. Proper bay cleaning will reduce the possibility of slipping or similar accident in the car wash bay. Cleaning is the responsibility of the car wash operator. No one should climb or stand on this equipment for any reason. All personnel should read; be familiar with; and observe the "CAUTION" AND "WARNING" decals and labels placed on the equipment and its various parts. All persons should stay clear of the equipment when it is operating. All shields, guards, nuts, bolts, and screws should be kept in place and securely tightened. SERVICE PERSONNEL ARE TO PERFORM LOCKOUT AND TAG SAFETY REQUIREMENTS. NOTE: OSHA regulations are required in the U.S. only. For safety reasons, RYKO recommends following these procedures at ALL locations (including those outside the U.S.) when installing or performing service maintenance on equipment and machinery. Never place hands in any moving portion of the equipment. Use appropriate protective gear as directed on container labels when handling chemicals and solvents. Always handle and dispose of empty chemical containers properly. Refer to the container label for handling and disposal guidelines. When combustible materials or substances (such a gas, gas fumes, oil, etc.) may potentially come in contact with electrical equipment, fire prevention measures and appropriate safety precautions must be taken. When installing or operating any RYKO equipment, adhere to all fire and safety rules/regulations per local, state, and national authorities. Page 1

7 BASIC REQUIREMENTS AND SPECIFICATIONS AIR Minimum 3/8" ID (10 mm) line at 50 PSI (3,5 bars 345 KPA) at 1.5 CFM (45 LPM) flow. Maximum Pressure at 150 PSI (10,4 bars, 1035 KPA) WATER 1 inch service, 40 PSI (275 KPA) minimum at 15 GPM (57 LPM) flow rate. (There should be no restrictions in the service line. Maximum pressure is 100 PSI.) IMPORTANT! WHILE A 1 INCH SERVICE LINE IS PREFERRED, IT IS REALIZED THAT THE EV II-B MAY BE INSTALLED TO AN EXISTING SYSTEM WITH 3/4 INCH SERVICE. FOR THIS REASON A 3/4 INCH FITTING IS SUPPLIED. Note: Water usage for a given car wash machine and wash cycle will depend on the length of the vehicle being washed, the length of the rinse cycle, and the specific options that have been installed. WATER CONSUMPTION The EV II- B consistently and appreciably lessens the consumption of fresh water when installed with a RYKO vehicle wash machine. On an average, the car wash machine uses approximately 15 to 20 gallons of fresh water for each single pass wash cycle, or 30 to 37 gallons for each double pass wash cycle. If the EV II-B is installed, fresh water consumption for each wash of these cycles would be reduced to approximately 4 to 7 gallons. ELECTRIC Minimum Circuit Amps with Rinse Pump: 208/230V, 60 HZ, 3 phase, 15.0 AMPS 460V, 60 HZ, 3 phase, 7.5 AMPS 380/415V, 50 HZ, 3 Phase, 10.0 AMPS Note: All control wire must be 14 gauge minimum. Note: Electricity usage will vary, depending on the machine used, and the wash cycle. IMPORTANT! INSTALLATION OF THIS EQUIPMENT REQUIRES A FUSED DISCONNECT WITHIN VIEW OF THE EV II-B AS REQUIRED BY U.L. PHYSICAL SPECIFICATIONS CABINET DIMENSIONS (APPROXIMATE) Height Width Depth 43 (1090 mm) 21 3/4 (550 mm) 12 3/4 (325 mm) Page 2

8 SPECIFICATIONS: PARTS/OPTIONS SEPARATOR: WASH PUMP: AUTO- RECIRCULATION: 2 HP, 3 Phase, 60 Hz 3 HP, 3 Phase, 50 Hz Flow Rate - 19 to 32 GPM See Terms and Definitions and EV II-B Adjustment Instructions in the Service Manual. CHLORINATOR: See Terms and Definitions and EV II-B Adjustment Instructions and Chlorinator System Option in the Service Manual. UNDERWRITERS LABORATORIES LISTING The Underwriters Laboratories industrial control panel listing is standard on all RYKO Environmentalist II- B (EV II-B) units. Parts or components located in the wash bay terminal box, high voltage panel or low voltage panel must be replaced or repaired with identical equipment. Underwriters Laboratories Listing #E71242(N) (Category Reference Number) Note: Replacement with parts or components not identical to original equipment, or modified from original condition will void U.L. listing. Page 3

9 INSTALLATION RECOMMENDED UNLOADING PROCEDURES Unload the EV II-B according to directions on the Recommended Unloading Procedures document provided on the equipment shipment. Note: This document is used for multiple products. Be sure to locate the section with instructions specific to the EV II-B. INSTALLATION REQUIREMENTS OSHA INSTALLATION REQUIREMENT: IMPORTANT! The Occupational Safety and Health Administration (OSHA) has issued regulations, 29 CFR , requiring the use of locks and/or tags prior to performing service or maintenance on equipment and machinery. A lockout is a device which provides positive means for rendering a switch, valve, raised load, coiled spring or any energy source, (air, water, or electric) inoperative. Lock out is a necessary step for ensuring worker safety prior to performing maintenance or service. For this reason lockouts and/or tags must be used per OSHA regulations, 29 CRF If in doubt on these required regulations, contact your local RYKO Representative for assistance before proceeding with installation. Refer to the Installation Tool Check List in this manual before beginning installation. The EV II-B pumping assembly is installed next to the same wall where the machine wash bay terminal box is mounted (near the exit end of the tracks or in the utility room). For the cabinet installation location, refer to the Typical Bay Reclaim Tank Layout drawing. IMPORTANT! RYKO RECOMMENDS THAT A 30 INCH CLEARANCE EXIST BETWEEN THE MACHINE TRACK AND THE WALL. A MINIMUM OF 23 INCHES IS NECESSARY TO AVOID DAMAGE OCCURRING TO THE EV II- B. IF THE BAY HAS LESS THAN THE MINIMUM CLEARANCE, THE EV II-B PUMPING UNIT MUST BE INSTALLED IN AN ADJOINING BAY OR UTILITY ROOM. Note: Minimum length, width, and height must be increased if other accessories are installed. A PRIVATE CONTRACTOR must supply the drainage pit and two (2) 1,000 gallon (3785L) or two (2) 500 gallon (1900L) underground settling tanks. The size of the tanks installed depends on the number of vehicles washed per hour. Refer to the Typical Bay Reclaim Tank Layout drawing in this manual for specifications of tanks applicable to EV II-B systems. Construction of these tanks may be pre-cast or cast-in-place concrete or similar material. Both tanks are installed underground in accordance with all applicable local and state regulations. Capacity dimensions for tanks may vary, but total combined recommended capacity should be approximately 1,000 to 2,000 gallons. The tank capacity recommendation depends upon the number of vehicles washed per hour. Higher volume car wash locations should consider larger volume tanks. Note: For recommended bay layout dimensions, refer to the Typical Bay Reclaim Tank Layout drawing. Due to the buildup of sediment and road salt inside the compartments, periodic cleaning and flushing of the compartments, foot valve and strainers is necessary. Page 4

10 To provide easy access for cleaning and flushing of each compartment, installation of one manhole per compartment is recommended. Installation of these manholes is the responsibility of a PRIVATE CONTRACTOR. The frequency of cleaning will depend on climate and wash volume. See Recommended Maintenance and Chlorinator Operation in the Service Manual. When installation of the EV II-B is complete, seal and test each compartment for leakage before operating the system. In areas where cold weather exists, underground plumbing must be protected against freezing. Local codes must be reviewed for specific installation requirements. Install the floor drain and sand trap in accordance with local and state regulations and codes. The standard one-inch water line to the machine is not necessary when the machine is equipped with an EV II-B. OTHER AREAS OF EV II-B INSTALLATION THE CUSTOMER must supply a 2 inch (2") pipe from the second underground tank to the EV II-B pumping assembly. This is a suction line. If an above ground strainer option is installed, no foot valve or strainer is required in the underground tank. If this location is not using an above ground strainer option, a foot valve and strainer, positioned one foot, six inches (1' 6") from the inside bottom of the tank, must be assembled to the pipe. Refer to the Typical Bay Reclaim Tank Layout drawing for foot valve recommendations. A distance of eight feet (8') or less is recommended from the foot valve to the surface of the wash bay floor. The pipe should emerge from the floor as close to the EV II-B pumping assembly as possible. The vertical draw should not exceed sixteen feet (16'). THE CUSTOMER should take precautions to prevent freezing of the pumping assembly and piping during cold weather. THE CUSTOMER must supply the utilities to the EV II-B pumping assembly. This includes installing a 3/4 inch water line at 40 PSI from the municipal water supply. Electrical service to the EV II-B must be provided in addition to the standard electrical service for the machine. A PRIVATE CONTRACTOR must supply watertight conduit and seven (7) #14 AWG wires from the wash bay terminal box to the EV II-B electrical box located inside the reclaim panel. THE CUSTOMER must install a backflow prevention valve if needed or required. The backflow prevention valve helps prevent water from flowing back in to the city water line and must be installed according to local codes. This valve is not available through RYKO and must be ordered from another source if installation is required. Typical Bay Layout drawings are supplied to demonstrate possible tank placement, dimensions and locations. Contact a RYKO representative for information regarding unusual installations. Page 5

11 INSTALLATION Refer to the Auto-Recirculation EV II-B Installation drawing and any other drawings as they apply to bay layout and/or installation of options and the instructions provided in this manual to complete installation of the EV II-B. With exception of the steps listed below, follow normal assembly and installation procedures to install the machine. 1. The one inch water supply line to the machine is preferred, but not required. If 3/4 service exists it may be utilized. 2. The 3/4" inch conduit and seven #14 gauge wires must be installed from the wash bay terminal box to the EV II-B pumping assembly. Determine the location of the pumping assembly before beginning installation. 3. The EV II-B should be placed as close to the 2" stubbed line as possible. Determine the line location before starting installation. The maximum pump draw is 16 vertical feet (16'). IMPORTANT! WATER HOSES FROM THE MACHINE REACH A DISTANCE OF 25 FEET FROM THE BOOM MOUNT. IF THE PUMPING ASSEMBLY IS INSTALLED A DISTANCE GREATER THAN 25 FEET FROM THE CAR WASH, ADDITIONAL PLUMBING MUST BE SUPPLIED BY OTHERS. INSTALLED EV II-B The picture below shows the EV II-B (with the cover removed) on completion of installation. Page 6

12 ASSEMBLY AND INSTALLATION PROCEDURES Note: EV II-B assembly parts and fastening materials described in the steps that follow are provided. 1. Position and secure the assembled EV II-B to the wall, at the recommended locations shown in the EV II-B Typical Bay Reclaim Tank Layout drawing. 2. Assemble / install the EV II-B according to all information (including NOTES) on the Auto- Recirculation / EV II-B Installation drawing. IMPORTANT! 1" AND 3/4" FITTINGS ARE PROVIDED TO ALLOW INSTALLATION FOR EITHER 1" OR 3/4" SERVICE. CONNECT THE 1" OR 3/4" HOSE FROM THE MUNICIPAL WATER SUPPLY LINE TO HOSE BARB AND SECURE WITH CLAMP. IMPORTANT! CUT A LENGTH OF 1" HOSE (NOT SUPPLIED) LONG ENOUGH TO BE CONNECTED TO THE PURGE VALVE ON THE BOTTOM OF THE CYCLONE SEPARATOR AND RUN TO COMPARTMENT II. 3. Wire the EV II-B in according to instructions on the Standard Bay Electrical Installation drawing pertaining to the vehicle wash machine with which the EV II-B is installed. 4. Install conduit and wires from the wash bay terminal box to the pumping assembly terminal box. 5. Fill the underground tanks with water. 6. Prime the pump suction plumbing (Refer to the Service Manual). Verify that the piping and foot valve do not leak. Page 7

13 U.S. / METRIC CONVERSION INFORMATION The information below provides common conversions used when metric measure is required for installation rather than U.S. measure. LENGTH WEIGHT 1 inch = 2.54 centimeters = 25.4 millimeters 1 pound = kilograms (kg) 1 foot = meters = Newton's (FORCE) 1 mile = kilometers = 1609 meters 1 kilogram = pounds 1 centimeter = inches (cm) = ounces 1 millimeter = inches (mm) TEMPERATURE 1 meter = 100 centimeters (m) C =.556 (F - 32) = 1000 millimeters F = 1.8 (C + 32) = inches MOMENT = feet 1 foot pound = Newton Meters 1 kilometer = miles (km) = Joules VOLUME PRESSURE 1 ounce = milliliters (ml) 1 pound / square inch = bars 1 quart = liters (also liters) = KPA (Kilo Pascals) 1 gallon = liters = 6895 Newton/sq m 1 cubic inch = cubic centimeters 1 KPA = PSI 1 cubic foot = liters 1 bar = pounds/square inch 1 milliliter = 1 cubic centimeter = ounces = kilograms/square centimeter 1 cubic foot = 7.5 gallons = mm Hg at 0 Deg. C 1 liter =.001 cubic meter = 100 KN/M2 = 1000 cubic centimeters (Note: 1 bar is approximately 1 atmosphere of pressure. = cubic inches = quarts ELECTRICAL POWER = gallons Horse Power (HP) = W 1 cubic meter = cubic feet = US gallons FLOW 1 gallon/minute = liters/minute = liters/second 1 gallon/hour = milliliters/minute 1 cubic foot/minute = liters/minute 1 cubic foot/minute = liters/second 1 ounce (US fluid) /second = liters/second = cc/sec = milliliters/sec 1 liter/minute = gallons/minute 1 liter/second = gallons/minute = cubic feet/minute 1 cubic centimeter/second = oz/sec Page 8

14 WIRE SIZES Wire size is expressed in square millimeters rather than AWG number. Below is an approximate Cross Reference AWG to mm sq. CONDUIT SIZES AWG mm sq. AWG mm sq. 30 0, ,5 28 0, ,5 26 0, , , , , , , Inch Size Metric Steel Metric PVC 1/2" 16 mm 16 mm 5/8' 16 mm 16 mm 3/4" 20 mm 20 mm 1" 25 mm 25 mm 1 1/4" 32 mm 32 mm 1 1/2" 38 mm 2" 50 mm Page 9

15 INSTALLATION TOOL CHECK LIST The Installation Tool Check List that follows consists of recommended tools, equipment, and supplies that should be readily available when installing this product. Having these tools available when beginning installation will help to eliminate costly delays in the installation of wash equipment and the options ordered. Recommended tools, equipment, and supplies for RYKO installations. QUANTITY DESCRIPTION 1 Roto Hammer (heavy duty) 1 1/2 X 16 Roto Hammer Bit 1 Heavy Duty Extension Cord (100 ) 1 All Purpose Drill 1 Set Drill Index, 1/16 thru 1/2 (by 64th s) 1 8 ft. Step Ladder 1 Hacksaw / with Extra Blades 1 30 ft. Tape Measure 1 Adjustable Wrench (12 ) 1 Utility Knife / with Extra Blades 1 Channel Lock Pliers 1 18" Pipe Wrench 1 12 Pipe Wrench 1 Flat Screwdriver Set 1 1/8 Wide Flat Screwdriver (for terminal connections) 1 Needle Nose Pliers 1 Set 1/4 thru 1 End Wrenches 1 3/8 Socket Set with Extensions 1 Wire Stripper 1 2 ft. Level As Required 1/2 X 2 1/4 Compression Anchors (part # ) Page 10

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20 Installation Manual For Work Order Page IA-5 INSTALLATION START-UP TEST PROCEDURE CHECKLIST FOR USE WITH ENVIRONMENTALIST II-B MODELS X. CAUTION! INSTALLATION OF THIS EQUIPMENT MAY REQUIRE PERSONNEL TO CONNECT HIGH VOLTAGE WIRING AND TO WORK ABOVE FLOOR LEVEL. EXTREME CARE MUST BE EXERCISED FOR PERSONAL SAFETY. FOLLOW LOCAL CODES, SAFETY REGULATIONS, AND OTHER SAFETY REQUIREMENTS AS LISTED IN THE INSTALLATION MANUAL. EQUIPMENT REQUIRED: Voltmeter CHECK OPERATION TO PERFORM 1. Verify equipment arrived at installation site in proper condition. 2. Verify that the equipment has been installed per the appropriate installation drawings and instructions. 3. Verify that the voltage supplied to the equipment is correct per the appropriate installation drawings and instructions within 10% as read on the voltmeter. 4. Verify that water supplied to the equipment is correct per the appropriate installation drawings and instructions. 5. Turn the PUMP SWITCH to TEST to verify proper wash pump motor rotation. 6. Turn the CONTROL SWITCH and the PUMP SWITCH to NORMAL, arm the car wash machine and ensure that water is delivered to the car wash by the EVII-B during the appropriate cycles. 7. Turn the CONTROL SWITCH to FRESH WATER WASH, arm the car wash machine and ensure that fresh water is delivered to the car wash by the EVII-B during the appropriate cycles. 8. Turn the CONTROL SWITCH and the PUMP SWITCH to NORMAL, then the wash pump will start for auto-recirculation about 5 minutes after the last wash. (opt) (opt) 9. If frost protect is present, verify that the reclaim frost protect and the purge valves open when they receive the frost protect signal from the car wash machine. 10. If undercar wash is present, verify that the undercar wash is spraying adequate reclaim water flow and pressure during the undercar wash cycle. INSTALLATION START-UP TEST PROCEDURE NO REV. -- ECO APRV RDC DATE 1/15/96 Page 1 of 2

21 (opt) (opt) 11. If frost protect is present for the undercar wash, verify that the undercar blowout valve opens when it receives the frost protect signal from the car wash machine. 12. If there is a chlorinator installed with this EVII-B, verify that water discharges from the chlorinator outlet polytube whenever the wash pump operates. The Installation Start-up Test Procedure for the Environmentalist II-B is now complete. INSTALLATION START-UP TEST PROCEDURE NO REV. -- ECO APRV RDC DATE 1/15/96 Page 2 of 2

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