System Background and Operation

Pty Limited 1/48 Racecourse Road RUTHERFORD NSW 2320 Telephone: (02) 4932 0111 Facsimile: (02) 4932 0222 E-mail:hyden@hydeneng.com.au ABN: 17 129 010 902 ENVIROSPRAY Manual Manual Number: 06500976A Manual Date: June 2011 System Background and Operation Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 1

Reference Number Contents Topic Page Number 1 1.1 2 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.1.11 2.1.12 2.1.13 2.1.14 2.1.15 2.1.16 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.3.1 2.4 2.4.1 2.5 2.5.1 2.5.2 2.5.3 2.5.4 Enviro-Spray Background System Operation System Controls Spray Toggle Switches Auxiliary Outlets Switch Using the Pause Function Power Indicator Vari-Spray Buttons Road Speed Spot Spray Display Window Pedal Indicator Centre Spray Indicator Left Spray Indicator Right Spray Indicator Cannon Switch/s Cannon Controls Foam Injection Switch (optional) Jet/Fog Switch (optional) Using the Spray System Basic Spraying Spot Spraying Road Speed Control Combination Spraying Using the Remote Cannon Basic Cannon Operation Using the Auxiliary Auxiliary Systems System Controls Tank Level Monitoring System Speed Sensor Monitor Motor Filter Sensor Motor Failing Sensor 3 3 5 5 5 5 5 5 6 6 6 7 7 7 7 7 7 7 7 7 8 8 10 13 15 19 19 21 21 22 22 23 24 24 Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 2

1 Enviro-Spray 1.1 Background Enviro-spray was specifically developed to be a plug and play system that optimises the use of limited water supplies while still maintaining the dust control barrier required by regulations. The user interface has been simplified by replacing the old dial type control with a user-friendly up-down push button control, foot pedal stop-start switch and LCD display. The Enviro-spray push button control sets the water flow rate, road speed and spot spray distances while constantly measuring the water level, filter condition and motor condition. The system can be preset to have default water flow rates, road speed settings and spot spray distances so that the operator may simply select road speed, spot spray or both and drive while the Enviro-spray system takes control. It will stop and start the water flow at intersections and automatically adjusts the water flow rate as the machine speeds up and slows down while also stopping and starting to provide the set wet and dry distances. Night time dust control has always been a daunting task for operators as they could not see the spray while driving and constantly had to adjust the flow control dial as they sped up and slowed down. The Enviro-spray road speed control has changed the face of night time dust control by giving the operator the confidence to preset the system to suit the conditions prior to driving and can have confidence that the Enviro-spray system will do the job. Enviro-spray also converted the first response capability of a standard water truck to a new level giving water throw in excess of 70-meters with an automatic foam injection system adjusting the foam to suit the desired water rate and this increases the efficiency of the limited foam supply. The Enviro-spray foam injection system also allows the use of multiple outlets so that foam may be simultaneously supplied to all water cannons, fire hose reel and Excavator backup systems giving the system the ability to become the hub of the fire fighting response. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 3

Maintenance was also kept top of mind in the development of the Enviro-spray system and this has been optimised by the use of separate modules for each key component, oversize filtration and with conditional indicators giving feedback to the operator. Each key control valve used in the Enviro-spray system has its own set of pressure test points and pressure gauge together with manual overrides so that diagnostics can be performed using these test points while following the simple diagnostic tree on the door of the control valve box. The system can be manually overridden if required to allow maintenance to be scheduled at a convenient time. Connection of the Enviro-spray hydraulics involves fitting the Enviro-spray soft start sequence valve in the line from the hoist pump pressure filter and connecting the return line from the Enviro-spray water pump module to the original hoist valve. There is no loss of brake cooling and the soft start sequence valve prevents the usual shock load when starting the water system since there is adequate pressure to cause the water pump to slowly rotate while unloaded. The Enviro-spray system also drops the average running pressure of the hoist pump to below 70-bar (1000-psi) in place of the 175-bar (2500-psi) seen with flow control systems and this significantly reduces the wear on the hoist pump and removes the overheating problem commonly associated with water truck hydraulics. The filtration system fitted to the Enviro-spray water pump module works as a full flow kidney system filtering the hydraulic oil to 20-micron. The basic system consists of a hydraulic pressure sequence valve and water pump module with an electric control system to provide all the basic features such as water rate proportional to road speed, fixed flow rate independent of engine speed and a positive start and stop spot spray with adjustable wet/dry distances. Options such as Enviro-spray foam injection, spray head controls, water cannon controls and water level monitoring can all be added to realise the full potential of the Enviro-spray system and are simply fitted and plugged into the control system. The backbone of the system is the large variable motor that controls the speed of the water pump and replaces the complex and troublesome flow control valves that overheat the system and limit the power available. The control system utilises closed loop technology to set the water rate and thus has made it possible to enhance operator control with features such as, water rate proportional to road speed, fixed rate independent on engine speed and positive start and stop spot spray with adjustable wet/dry distances. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 4

2 System operation 2.1 System controls 2.1.1 Spray Toggle Switches (typical 5 spray system illustrated, layout may vary) Spray System Switch This is the main power switch used to turn the Enviro-spray System on. Spray Nozzle Switches These switches are used to turn on the corresponding spray heads. A typical system may have from 3 up to 6 spray heads. 2.1.2 Auxiliary Outlets Switch This switch is used to turn the spray system on without turning spray heads or remote cannon on. This is primarily used in conjunction with a manual cannon or hose reel. 2.1.3 Foot switch This is used as a master control switch by turning all sprays and pump off in one action. It will also turn cannon or auxiliary outlets off. 2.1.4 Power Indicator Green indicator will be on while the spray system is switched on. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 5

2.1.5 Vari-Spray Buttons The increase button steps up the variable spray water volume by one step with each button push. The maximum setting will be as was set during the electric default system setup procedure. LOW, 20%,40%, 60%, 80%, HIGH The decrease button steps down the variable spray water volume by one step with each button push. HIGH, 80%, 60%, 40%, 20%, Low. NOTE: Maximum is only set for sprays not for the cannon or auxiliary water volume. 2.1.6 Road Speed The yellow road speed button switches between full Vari-rate water volume control and road speed variable controlled water volume. The yellow road speed indicator will be on when the road speed function is turned on. 2.1.7 Spot Spray The red spot spray button turns the distance based spot spraying feature on or off. The red spot spray indicator will be on when the spot spray function is turned on. Increase spot spray wet distance by one step with each button push. 5M/5M, 7M/7M, 10M/10M, 15M/15M, 25M/25M, 50M/50M Decrease spot spray wet distance by one step with each button push. 50M/50M, 25M/25M, 15M/15M, 10M/10M, 7M/7M, 5M/5M Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 6

2.1.8 Display window Messages will be displayed in this window to advise the status of spray operations. 2.1.9 Pedal Indicator The Pedal indicator will show the status of the foot pedal (On or Off). The foot pedal will always default to on when the spray system is turned on. 2.1.10 Centre spray indicator The Centre spray indicator will show the status of the centre spray head (On or Off). 2.1.11 Left spray indicator The Left spray indicator will show the status of the left spray head/s. (On or Off). 2.1.12 Right spray indicator The Right spray indicator will show the status of the right spray head/s (On or Off). 2.1.13 Cannon Switch/s The Cannon Switches will turn the spray system on and turn the chosen cannon on in one action. 2.1.14 Cannon Controls The Joystick is used to position the selected cannon in the direction of the required water stream. The cannon selector switch is used to operate the selected cannon functions, Up/Down, Left/Right, Jet/Fog and may be a rotary switch in some cases. 2.1.15 Foam Injection Switch The Foam switch starts the foam injection system (if fitted) with the volume automatically adjusted to suit the water volume set by the Vari-spray control rate. The foam will not inject if the cannon or auxiliary switches are not on. 2.1.16 Jet / Fog Switch The Jet / Fog switch (if fitted) changes the cannon nozzle to a fog or to a jet stream. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 7

2.2 Using the spray system 2.2.1 Basic spraying Step1) Turn the Spray System On Turn the spray system on by switching the SPRAY SYSTEM toggle switch to the ON position. The system will go through a short startup process and the display will show System Standby. Step2) Select which sprays you require Turn the required spray switches on and the display indicators will show which spray heads have been activated. Note: in a system with more than 3 spray heads adjacent spray heads may share an indicator. e.g. For the illustrated 5 spray system, switching on either the left or left-inner spray will illuminate the left display indicator. The screen will also display the default Vari-Rate (water volume) that the sprays have started at. Note: The default Vari-rate was set during the electric default system setup procedure to suit the average operating conditions. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 8

Step3) Using the Pause Function. The Pause Switch is used to stop the pump and sprays in one action. The display will show Sprays Stopped. Use the Pause Switch again and the system will revert back to the setting prior to operating the Pause Switch. Note: Systems are either fitted with a Foot Pedal or Toggle Switch to operate the Pause Function as requested on installation. Step4) Adjusting the Vari-rate Use the Vari-spray increase and decrease buttons to change the water volume as required. The display will show the Vari-rate that has been selected. Low, 20%, 40%, 60%, 80% or High Note: Maximum Vari-rate is set during commissioning via the setup menu and may be change by your technical department. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 9

2.2.2 Spot spraying Step1) Turn the Spray System On Turn the spray system on by switching the SPRAY SYSTEM toggle switch to the ON position. The system will go through a short startup process and the display will show System Standby. Step2) Select which sprays you require Turn the required spray switches on and the display indicators will show which spray heads have been activated. Note: in a system with more than 3 spray heads adjacent spray heads may share an indicator. e.g. For the illustrated 5 spray system, switching on either the left or left-inner spray will illuminate the left display indicator. The screen will also display the default Vari-rate (water volume) that the sprays have started at. Note: The default Vari-rate was set during the electric default system setup procedure to suit the average operating conditions. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 10

Step3) Using the spot spray. Spot Spraying is based on distance rather than time and as such should be fully understood before operating. The Spot cycle is based on equal distances such that wet distance and dry distance are as per the selection. The selection of this distance is explained in Step 4 The time that the sprays are on is dependant both road speed and wet/dry distance selected. For example, if the wet/dry distance selected is 50M/50M and the truck is traveling at 30kph then the time that the sprays will operate is: Time on (wet) = 6 seconds, Time off (dry) = 6 seconds But if the same wet/dry distance is selected and the truck is traveling at 10kph then the time that the sprays will operate is: Time on (wet) = 18 seconds, Time off (dry) = 18 seconds Vari Rate = 60% Spot = 50M/50M The advantage of this system is that the wet spot distance will be maintained regardless of truck speed. Whether higher speeds on haul roads or lower speeds on ramps the distance selected will remain constant. Note: Short Spot lengths are ineffective if the road speed is beyond the systems ability to open and close the spray nozzles. For example if the road speed is 20kph then the minimum effective Spot length that should be selected is 7M/7M. This may vary slightly between systems. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 11

Step4) Adjusting the Spot Spray. There are 6 different Spot Spray wet/dry distances available that are selected by pushing the appropriate button to either increase or decrease the current setting. The system has been setup for your site with a default wet/dry distance. This can be changed easily by using the buttons provided. The selectable Spot Spray wet distances are: 5M/5M, 7M/7M, 10M/10M, 15M/15M, 25M/25M, 50M/50M The Display will show the new Spot distance as it is changed Vari Rate = 60% Spot = 50M/50M Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 12

2.2.3 Road speed control Step1) Turn the Spray System On Turn the spray system on by switching the SPRAY SYSTEM toggle switch to the ON position. The system will go through a short startup process and the display will show System Standby. Step2) Adjust the Vari-rate. Set the maximum Vari-spray rate required by using the increase decrease buttons until the desired maximum water rate has been selected. This maximum Vari-rate becomes the maximum water rate when the machine road speed reaches 30kph or above. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 13

Step3) Start road speed control Road Speed Spraying is used to automatically adjust the water volume from the sprays based on the current road speed. The road speed controlled water volume ramp will start the sprays and pump automatically when the machine road speed reaches 2kph and will increase the Vari-rate proportionally as the machine road speed increases up to 30kph and at this point the system will be at the maximum Vari-rate as selected in Step2. To turn this feature on simply push the yellow pushbutton and the yellow LED indicator will turn on. The display will show the preset maximum Vari-rate and Road Speed On The advantage of Road Speed controlled sprays is the ability to prevent over watering at lower speeds while maintaining sufficient water at higher speeds. The added feature of automatic spray stop when the truck stops prevents flooding at intersections. Step4) Select which sprays you require Turn the required spray switches on and the display indicators will show which spray heads have been activated. Note: in a system with more than 3 spray heads adjacent spray heads may share an indicator. e.g. For the illustrated 5 spray system, switching on either the left or left-inner spray will illuminate the left display indicator. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 14

2.2.4 Combination spraying Step1) Turn the Spray System On Turn the spray system on by switching the SPRAY SYSTEM toggle switch to the ON position. The system will go through a short startup process and the display will show System Standby. Step2) Adjust the Vari-rate. Set the maximum Vari-spray rate required by using the increase decrease buttons until the desired maximum water rate has been selected. This maximum Vari-rate becomes the maximum water rate when the machine road speed reaches 30kph or above. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 15

Step3) Start road speed control Road Speed Spraying is used to automatically adjust the water volume from the sprays based on the current road speed. The road speed controlled water volume ramp will start the sprays and pump automatically when the machine road speed reaches 2kph and will increase the Vari-rate proportionally as the machine road speed increases up to 30kph and at this point the system will be at the maximum Vari-rate as selected in Step2. To turn this feature on simply push the yellow pushbutton and the yellow LED indicator will turn on. The display will show the preset maximum Vari-rate and Road Speed On The advantage of Road Speed controlled sprays is the ability to prevent over watering at lower speeds while maintaining sufficient water at higher speeds. The added feature of automatic spray stop when the truck stops prevents flooding at intersections. Step4) Select which sprays you require Turn the required spray switches on and the display indicators will show which spray heads have been activated. Note: in a system with more than 3 spray heads adjacent spray heads may share an indicator. e.g. For the illustrated 5 spray system, switching on either the left or left-inner spray will illuminate the left display indicator. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 16

Step5) Starting the spot spray. Spot Spraying is based on distance rather than time and as such should be fully understood before operating. The Spot cycle is based on equal distances such that wet distance and dry distance are as per the selection. The selection of this distance is explained in Step 4 The time that the sprays are on is dependant both road speed and wet/dry distance selected. For example, if the wet/dry distance selected is 50M/50M and the truck is traveling at 30kph then the time that the sprays will operate is: Time on (wet) = 6 seconds, Time off (dry) = 6 seconds But if the same wet/dry distance is selected and the truck is traveling at 10kph then the time that the sprays will operate is: Time on (wet) = 18 seconds, Time off (dry) = 18 seconds Vari Rate = 60% Spot = 50M/50M The advantage of this system is that the wet spot distance will be maintained regardless of truck speed. Whether higher speeds on haul roads or lower speeds on ramps the distance selected will remain constant. Note: Short Spot lengths are ineffective if the road speed is beyond the systems ability to open and close the spray nozzles. For example if the road speed is 20kph then the minimum effective Spot length that should be selected is 7M/7M. This may vary slightly between systems. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 17

Step6) Adjusting the spot spray. There are 6 different Spot Spray wet/dry distances available that are selected by pushing the appropriate button to either increase or decrease the current setting. The system has been setup for your site with a default wet/dry distance. This can be changed easily by using the buttons provided. The selectable Spot Spray wet distances are: 5M/5M, 7M/7M, 10M/10M, 15M/15M, 25M/25M, 50M/50M The Display will show the new Spot distance as it is changed Vari Rate = 60% Spot = 50M/50M Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 18

2.3 Using the remote cannon 2.3.1 Basic cannon operation (typical 2 cannon system illustrated, layout may vary) Step1) Moving the cannons The direction that the selected cannon is pointing can be adjusted using the joystick control and cannon selector switch. For Hydraulic cannons the machine must be running. Warning: It is important to adjust the direction prior to starting the system as the system is capable of causing serious injuries or damage to anything in the path of the stream. A minimum safe working distance will be specified by your site rules. Step2) Starting the remote cannons To start a cannon you simply switch the respective cannon switch to the on position and the system will automatically start up (after a short startup process) with the Vari-rate set at the default rate. The display screen will show Cannon On showing the status of the system. Step3) Adjusting the Vari-rate After the cannon has started you can now adjust the Vari-rate to the desired level or just leave it on the default setting. The Vari-rate will be displayed on the Display screen Adjusting the Vari-rate is done using the Vari-rate increase and decrease buttons until you reach the desired level. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 19

Step4) Cannon nozzle adjustment The Jet and Fog switch can be used to change the pattern of the cannon water spray from Jet to Fog or Fog to Jet. Step5) Using the Pause Switch with cannon The Pause Function can be used at any time to pause the Cannon water flow. Simply push once to stop and once again to restart. The display screen will always show the Cannon status when it is turned on. Step6) Using the Foam injection system The foam injection system (if installed) is an added tool for firefighting purposes. The foam will only operate when either the Cannon or the Auxiliary is on. When the Cannon is on and the Foam switch is turned on, foam will be directly injected into the main water flow. The percentage of foam injection is automatically adjusted by the control system to match the current Vari-rate. Low & 20% = Low Foam 20% & 60% = Medium Foam 40% & High = High Foam The current Foam injection will be momentarily displayed each time the vari-rate is changed and then will revert back to Cannon On. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 20

2.4 Using the Auxiliary 2.4.1 Auxiliary systems Step1) Using the auxiliary mode The Auxiliary Mode is provided so that any manual valve type devices (fire hose, manual cannon etc) can still be used with Vari-rate spray control and the foam injection systems. Care should be taken when using this mode that the auxiliary switch is not left on with no water flow for extended periods. The Spray System switch doesn t need to be on to operate in Auxiliary Mode. Turn the Auxiliary toggle switch on and the system will go through a short startup process and then water pressure will be available at the default Vari-rate set for your site. Step2) Using the Pause Function with Aux The Pause Function can be used at any time to pause the Auxiliary water flow. Simply push once to stop and once again to restart. For extended periods without water flow the Pause Function should be used to pause the system stopping the water pump. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 21

2.5 System controls 2.5.1 Tank level monitoring system Tank Water Level (if installed) will provide continuous indication and warnings of current tank levels. The display will be updated with the current water level every 10 seconds. If the display line is overwritten by another message the level gauge will return after 10 seconds. The exception to this is when the Cannon or Auxiliary Modes are on. In these modes the display will show either Cannon On or Auxiliary On and the Tank Water Level will still update every 10 seconds but will only stay visible for 5 seconds each time. When the Tank Water Level is down to 8% (last marker) the alarm will pulse twice and the Caution Tank Low message will be displayed followed by the Tank Water Level gauge. This will be repeated every 10 seconds until the tank is refilled. When the Tank Water Level is down to empty (no marker) the alarm will pulse three times and the Tank Empty message will be displayed. This will be repeated every 10 seconds until the tank is refilled or the system is turned off. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 22

2.5.2 Speed sensor monitor The Pump Motor Speed Sensor is a critical part of the spray control system. This sensor continually feeds back to the control module so that it will always know what the motor speed is doing. If this speed sensor fails or the wiring to it fails then the system will automatically change the Vari-rate back to Low to protect the motor and an operator warning will be displayed and the buzzer will sound three times. The system can still be used to output water but the Vari-rate will not be functional until the speed sensor fault is rectified. If the Speed Sensor fault should self rectify then the display will temporarily show the following screen before returning to the normal Vari-rate screen. If the Speed Sensor detects that the motor is running beyond its designed maximum speed the system will shut down and the screen will display Motor Overspeed. If this occurs the system should be checked to ensure that the water pump is primed with water and that the drive coupling has not failed. Motor Overspeed Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 23

2.5.3 Motor Filter sensor The system is fitted with a pressure filter that filters the oil going into the pump motor. This filter is fitted with a clogging indicator that is constantly monitored by the system. The Motor Filter Blocked fault alarm is a critical alarm that if ignored can cause contamination of the hydraulic oil. The effect of this could cause major component failure if not rectified. For this reason if a Motor Filter Blocked fault is detected the system will display the fault and sound the buzzer three times. It will also shut the system down so that it cannot be used until the fault is repaired. 2.5.4 Motor Failing sensor The system is fitted with a condition switch that monitors the flow rate from the case drain of the pump motor. The Motor Failing fault alarm is a critical alarm that if ignored can cause contamination of the hydraulic oil. The effect of this could cause major component failure if not rectified. For this reason if a Motor Failing fault is detected the system will display the fault and sound the buzzer three times. It will also shut the system down so that it cannot be used until the fault is repaired. Date Printed: 07/11/2011 Commercial-in-Confidence Page Number: 24