INSTALLATION MANUAL 2000WCY Pressure Cleaning System spraymastertech.com Spray Master Technologies is a quality product line of Assembled Products Corp. 115 E. Linden Rogers, Arkansas 72756 USA (479) 636-5776 Fax: (479) 636-3245 1-800-548-3373 www.spraymastertech.com ATTENTION: Specifications found in this manual subject to change without notice. Please read entire manual BEFORE beginning the installation. FOR COMMERCIAL USE ONLY. SMT-INSTALL-2000WCY-140116
OVERVIEW This manual is intended to provide general guidance for the installation of an SMT Pressure Cleaning System to an experienced equipment installer. Due to the wide variations of building structure and design into which the SMT system may be installed, as well as variations in the optional features of the system itself, it is not intended to be a comprehensive step-by-step installation procedure. The standard SMT Pressure Cleaning System will include an SMT 2000WCY pump which will be wall mounted utilizing a mating wall mount bracket. The hi-pressure water discharge from the pump will be connected to each of various remote stations with interconnecting hi-pressure. Remote electronic control of the pump is facilitated by interconnecting 24 volt control cable between the pump and remotes. The system includes some cleaning accessories such as a portable hose reel, hi-pressure hose(s), spraygun(s), and an SMT Hummer Jet Sr. parking lot/surface cleaner and other optional equipment. In all cases the pump and interconnecting hi-pressure lines must be installed such that they are not exposed to freezing temperatures to protect them from freeze damage. Remote stations may be installed surface mounted or recessed into the outside of an exterior wall as long as the plumbing to the remote station is run within the heated area of the building. The pump must be installed at a location that is accessible for servicing. It should not be installed above any equipment or materials that will be damaged or pose a safety hazard by exposure to water. Remote stations should be installed at convenient locations throughout the facility. The remote must be securely attached to the building structure to hold it in place as tension will be exerted on the remote station by the hi-pressure hose which will be connected to it during use. The hi-pressure interconnecting hoses will be run from the pump, to overhead above the ceiling and down inside the walls to the remote station. Some installation hardware is included. Additional hardware may be required that is not provided by the manufacturer. The following is a list of typical tools required for installation of an SMT Central Pressure Cleaning System: Common hand-tools 5/8, 11/16 and assorted combination wrenches Tubing cutter and tubing bender for 3/8 stainless steel tubing Cable Cutter, wire stripper, wire terminal-crimper Drill; drill-bits for masonry and/or wood; hole saws and driver bits Grinder (hand-held) with masonry blades INDEX Main Pump........................................ 3 Wall Mount Rack................................... 3 System Component Identification.................. 4 Wall Mount Bracket Install.......................... 5 Pump Frame Assembly Install...................... 6 Utility Service Requirements....................... 7 Water Supply Filter Install.......................... 7 Remote Station Install........................... 7-11 Hi Pressure Hose & Control Cable Install.........12-13 Master Control Panel Wiring Diagram..............14 Control Cable Splicing.............................15 Operational Tips (Starting/Testing)................15 Operational Testing...............................16 2 WWW.SPRAYMASTERTECH.COM i Pressure Interconnecting Hose Installation
MAIN PUMP (SMT2000WCY) continued from page 2 Once the location of the pump unit has been established and electrical and water service requirements are available at the site, the pump unit may be installed. Use the appropriate figure as a guide to install the following components. Figure 1 shows a typical pump installation. FIGURE 1 - Installed SMT 2000WCY Pressure Wash Unit 3 WWW.SPRAYMASTERTECH.COM
SMT 2000WCY SYSTEM COMPONENT IDENTIFICATION Refer to Figure 2 for the identification of the components of particular interest during installation of the SMT2000WCY Wall Mount Pressure Cleaning System. These components may be referred to during the description of the installation procedures. FIGURE 2 - SMT 2000WCY System Component Identification 4 WWW.SPRAYMASTERTECH.COM
WALL MOUNT BRACKET INSTALLATION- Refer to Figure 3 for installation of the wall mount bracket. Proper orientation of the Wall Mount Bracket is essential. A decal is attached to the bracket identifying the top of the bracket when properly oriented. If the decal is not present, use the following description of the bracket to identify the top. Note that the top crossmember of the wall mount bracket is toward the back of the frame while the lower cross-member is located toward the front of the frame. This orientation is necessary to install the pump and to keep the pump frame assembly parallel to the wall. The wall mount bracket must be secured to a wall that will support the weight of the pump - up to 200 pounds. Minimum 48 x 48 x ¾ plywood backing or equivalent is required in/on the wall at the desired height and location. The wall mount bracket will be attached to the wall with minimum ¼ hardware suitable for the wall construction type. Once the Wall Mount Bracket is installed, the Pump Frame Assembly can be mounted to it. Allowing for the clearances shown in Figure 3 will ensure the unit can be easily installed and fully accessed for preventive maintenance and service. FIGURE 3 - Wall Mount Bracket Installed (SMT 2000WCY) 5 WWW.SPRAYMASTERTECH.COM
PUMP FRAME ASSEMBLY INSTALLATION- Refer to Figure 4. The Pump Frame Assembly is heavy and should be lifted appropriately with lifting equipment or four-man lifting. The Pump Frame Assembly is equipped with u-channel cross-members that will nest over the cross-members of the Wall Mount Bracket previously installed on the wall. 1. Position the Pump Frame Assembly below the Wall Mount Bracket with the u-channel cross-members toward the wall. 2. Lift the Pump Frame Assembly into place so that the two u-channel cross-members of the Pump Frame Assembly nest over the two square tube cross-members of the Wall Mount Bracket. Align the holes in the u-channel cross-members with the holes in the square-tube cross-members of the wall mount bracket. 3. Install 1/4-20 x 1-1/2 bolts through the cross-members at four locations as shown in Figure 3. Install the washers and hex lock nuts to secure the bolts into place. 4. Attach the black water supply hose to the bulkhead fitting on the underside of the float tank support plate. Connect the other end of the water supply hose to the hose bib or to the optional water filter, if included. 5. Loosen one manifold plug on top of the unloader assembly discharge manifold for each remote station that will be connected. The plug will be removed and replaced with a hi-pressure remote station supply hose upon installation of the remote station. 6. Extend the chemical pickup tube down below the pump assembly for insertion into the chemical supply. 7. A qualified electrician may now connect the line power through the power service-disconnect to the Pump Assembly Master Control Panel. Note: The line service must be a dedicated circuit with a GFCI breaker in the main power panel. Figure 5 shows the Pump Frame Assembly properly installed on the Wall Mount Bracket. FIGURE 4 -SMT 2000WCY Pump Frame Assembly Installation on Wall Mount Bracket FIGURE 5 -Installed SMT 2000WCY Pressure Washer Unit 6 WWW.SPRAYMASTERTECH.COM
UTILITY SERVICE REQUIREMENTS- Electrical Requirements: Dedicated Circuit 208V, 30 amp, 1 phase, 60Hz GFCI Breaker in Main Panel Service Disconnect at the Pump Water Supply Requirements: ¾ Garden Hose Bib Minimum 5 GPM @ minimum 30PSI Cold Water (maximum 120 F) WATER SUPPLY FILTER ASSEMBLY INSTALLATION (OPTIONAL EQUIPMENT)- Mount the water supply filter assembly to the wall below the unit in a location that will allow easy replacement of the filter element. Note: High torque is sometime required to remove the filter bowl and will place stress on the mounting hardware. Secure the filter mount bracket to backing within the wall with hardware adequate to sustain the high torque required to remove the filter bowl. The Filter assembly must be located within the reach of the two six foot hoses from the hose bib supply and the pump input. Connect the black hose from the hose bib to the filter input labeled IN. Connect the second black hose between the water filter OUT port to the tank fitting on the underside of the pump unit. REMOTE STATION GENERAL INSTALLATION INFORMATION- Remote stations may be installed for either outdoor or indoor use. For outdoor installation, the remote panels will be securely attached to the exterior wall of the facility. For indoor installation, the remote station may be securely attached to any interior wall that will permit easy access and connection of hi-pressure hose. Remote stations are typically installed at a height centered at 48 above the finished floor. Remotes may be installed at any height but recommended height is between 32 to 60 above finished floor (AFF). The general location of each remote station within a facility was previously identified during the design of the system. The next step is to identify the specific location of the remote in the wall. Exact location can be affected by the type of wall construction and obstructions within the wall and local building codes. Where possible, avoid locations near electrical wiring, outlets and switched as well as other plumbing. FOR NEW CONSTRUCTION; a single straight 2 PVC electrical conduit with a long sweep elbow should be installed in the wall as a chase within which to run the hi-pressure supply hose and control cable. The PVC conduit should be secured vertically within the wall extending above the finished ceiling, down to just above and aligned with the opening in the wall for the remote station connection. The hose extending from the bottom of the chase, will attach to the rear of the remote station. The top end of the PVC conduit must extend above the interior wall or exit the wall above the ceiling in a position that will allow insertion of the 3/8 highpressure hose. Install a long sweep elbow at the top of the chase as necessary to exit the wall above the ceiling. FOR EXISTING FACILITIES; hoses and control cable should be run above the ceiling and down to the rear of the remote station. Where possible install a 2 PVC electrical conduit as a chase as described in the previous paragraph. If a chase is not practical, attempt to run the hose and control cable within the wall without the chase taking care to protect the hose from sharp edges and corners that may chafe and damage the hose. If running within an exterior wall, run hoses on the heated side of the insulation within the wall to protect the line from freezing. In many cases this may require an access panel on the inside wall behind the remote station for connecting the hose and control cable and for future servicing. If it is not possible to run the hose and control cable within the wall it will be necessary to run the hose and control cable on the surface of the back side of the wall from where the remote is located. Penetrate the wall 7 WWW.SPRAYMASTERTECH.COM
REMOTE STATION MODELS AND FEATURES Identify the model number of the remote station to be installed at each location. Select the applicable figure from the list below and use it to guide you through the installation of each model. REMOTE STATION MODEL See Figure SMT 300-5225, Remote, Surface, Key Switch.............................. Fig 6 SMT 300-5202, Remote, Recess, Key Switch, New Masonry, Rear Entry.............. Fig 7 SMT 300-5203, Remote, Recess, Key Switch, Retro Fit, Rear Entry................. Fig 8 SMT 300-5229, Remote, Recess, Key Switch, New Masonry, Top Entry.............. Fig 9 SMT 300-5225 Remote Installation for Hi-pressure Hose. (Refer to Fig. 6) Install a 2 PVC chase in the wall from above the ceiling and down to just above the 6 x 2.5 opening (This should be completed before wall closure) Upon verifying accessibility and a clear opening in the wall where the remote is to be installed, cut a 6 x 2.5 vertical slot centered at the location where the remote station is to be installed. Feed the 3/8 hi-pressure hose and control cable through the 2 PVC chase to the remote station opening Connect the hose to the plumbing assembly of the remote station using the additional elbow, coupling and nipple fittings provided for best fit. Use several wraps of Teflon tape on all threaded fittings. Connect the control cable to the switch leads on the remote station matching color to color (black to black, red to red, and green to green) Verify the remote panel will fit snugly against the wall without excessive tension on the hi-pressure hose. Apply a bead of silicone to the back side of the panel and attach the remote station panel securely to the wall. Use mounting hardware capable of sustaining the force and tension exerted on it while connecting and disconnecting the portable hose reel. FACTORY INSTALLED BY SMT DETAIL -A- 2.5" 24VAC CONTROL CABEL FROM PUMP HOSE CONTROL CABLE 6" Ceiling Conduit Straps HOSE 2" PVC CONDUIT OPEN TO BOTTOM OF CONDUIT DETAIL -A- FIGURE 6 - Remote Model 300-5225 Surface Mount, Key Switch, Hi-pressure Hose Supply 32" AFF Studded Wall 8 Typical WWW.SPRAYMASTERTECH.COM McDonalds Install
SMT 300-5202 REMOTE INSTALLATION, Recessed, New Masonry, Rear Entry (Refer to Fig. 7) Install a 2 PVC chase in the wall from above the ceiling and down to several inches above the remote station box opening. Align the chase above and to the right side of the opening. This should be installed before wall closure. The enclosure of this remote station is to be installed in the wall as the masonry wall is being constructed using the mortar grippers on the top and the bottom to hold it in place Connect the hi-pressure hose from main unit, feed it through the 2 PVC chase and connect it to the plumbing assembly in the remote station using several wraps of Teflon tape on the male fittings Connect the control cable to the switch leads in the remote station matching color to color (black to black, red to red, and green to green) Seal around the remote station enclosure with a bead of silicone caulk. Assemble the door-panel assembly to the front of the remote station Remote Station Box With Grippers Check Clearance For "J" Nuts Hose Hose From Pump From Pump WIRE WIRE 2" PVC Chase 2" PVC Chase CONCRETE OR CINDER BLOCK DRYWALL OR PANEL DRYWALL OR PANEL HIGH PRESSURE HOSE BRICK OR VENEERSTONE REMOTE STATION BOX HIGH PRESSURE HOSE REMOTE STATION BOX 6" OR LARGER 32"AFF 32"AFF STUD STUD PULL OUT FOR CONNECTING PLUMBING PULL OUT FOR CONNECTING PLUMBING Note: 2" PVC CHASES ARE REQUIRED FOR EACH REMOTE STATION AND ARE NOT QUOTED OR SUPPLIED BY SMT FIGURE 7 - Model 300-5202, Remote, Recessed, Key Switch, HP Hose Supply 9 WWW.SPRAYMASTERTECH.COM
SMT 300-5203 REMOTE INSTALLATION, Recessed, Retro Fit, Rear Entry (Refer to Fig. 8) Install a 2 PVC chase in the wall from above the ceiling and down to several inches above the 8 x 7.25 opening. Align the chase above and to the right side of the opening. This should be installed before wall closure. Upon verifying accessibility and a clear opening in the wall where the remote is to be installed, cut an 8 (W) x 7.25 (H) opening at the location where the remote station is to be installed. Place the mount plate adapter in the opening as shown in figure 8 and mark the eight large holes near the opening and in the bent flanges of the mount plate. Remove the mount plate and notch out the marked location for each hole. These notches are required to accommodate the J-nuts and mounting hardware for the remote box and the cover. Ensure the four J-nuts are installed on the bent flanges of the mount plate. Insert the mount plate adaptor with J-nuts installed into the opening and secure it with the ¼ hardware provided. Insert the remote box into the installed adaptor mount plate with the flanged lip down and the hole in the rear of the box located to the right. Install the ¼-20 x ½ screws through the side of the box into the J-nuts in the adapter mount plate and tighten securely. 8" ADAPTER MOUNT PLATE DRIVE RIVETS 7 1/4" TYPICAL EXISTING BRICK OR BLOCK WALL RETROFIT INSTALLATION. NOTE: DEPTH OF RECTANGLE CUTOUTS IS 4" PLUS Hose Hose From Pump From Pump WIRE WIRE 2" PVC Chase From Pump 2" PVC Chase BRICK OR STONE VENEER DRYWALL OR PANEL DRIVE RIVET CONCRETE OR CINDER BLOCK DRYWALL OR PANEL DRIVE RIVET MOUNT PLATE MOUNT PLATE HIGH PRESSURE HOSE REMOTE REMOTE STATION BOX STATION BOX HIGH PRESSURE HOSE 32"AFF 6" OR LARGER STUD 32"AFF STUD PULL OUT FOR CONNECTING PLUMBING PULL OUT FOR CONNECTING PLUMBING Note: 2" PVC CHASES ARE REQUIRED FOR EACH REMOTE STATION AND ARE NOT QUOTED OR SUPPLIED BY SMT FIGURE 8 MODEL 300-5203, REMOTE, RECESSED, KEY SWITCH, RETRO-FIT 10 WWW.SPRAYMASTERTECH.COM
XXXXX XXXXX SMT 300-5229 REMOTE STATION, Recessed, Top Entry Installation (Refer to figure 9) The enclosure of this remote station is to be installed in the wall as the masonry wall is being constructed using the mortar grippers on the top and the bottom to hold it in place A 2 PVC conduit should be installed as masonry wall is constructed. Align the 2 PVC conduit right above the hole in the enclosure. Using a long 2 conduit sweep elbow attach to PVC chase and protrude above ceiling out of wall in direction going towards the main unit. Connect the hi-pressure hose from the main unit, feed it through the 2 PVC chase and connect it to the plumbing assembly in the remote station using several wraps of Teflon tape on the male fittings Connect the control cable to the switch leads in the remote station matching color to color (black to black, red to red, and green to green) Seal around the remote station enclosure with a bead of silicone caulk. Assemble the door-panel assembly to the front of the remote station TUBING INSULATION CINDER BLOCK CONTROL CABLE REMOTE BOX 300-5229 XXXXX XXXXX 32"AFF MOTAR GRIPPER TYPICAL CINDER BLOCK WALL INSTALLATION Sweep elbow through wall above ceiling 2" Pvc Conduit Chase Align conduit chase centers over opening in top of remote box Cinder Block Remote Box Mortar Gripper 40" - 60" AFF 48" RECOMMENDED FLOOR Note: 2" PVC CHASES ARE REQUIRED FOR EACH REMOTE STATION AND ARE NOT QUOTED OR SUPPLIED BY SMT CS- 5229 B FIGURE 9 MODEL 300-5229, REMOTE, RECESSED, KEY SWITCH, TOP ENTRY 11 WWW.SPRAYMASTERTECH.COM
HI-PRESSURE INTERCONNECTING HOSE AND CONTROL CABLE INSTALLATION Refer to Figure 10. Hi-pressure water from the pump unit is distributed to the remote stations through 3/8 hi-pressure hose rated for 3000PSI or greater. Each remote station is connected directly to the pump discharge manifold using a dedicated hi-pressure supply hose. The hose must be installed and secured to the building structure so that it is not kinked or in contact with any sharp edges or corners. The hose will flex a small amount with fluctuating pressure and will be damaged if it is allowed to chafe against rough or sharp surfaces. Low voltage multi-conductor cable is used to interconnect the remote stations to the pump which will provide remote operation of the pump from any remote station location. This low voltage control cable is run along with and typically strapped to the hi-pressure supply hose running to each remote station. This 24 Volt wiring typically does not require enclosure in conduit. Check local code for verification. The control cable may be run simultaneously with the hi-pressure hose by strapping the cable to the hose as it is pulled into place. Leave an extra 12 inches of cable at the remote station end of the hose for connection to the control panel. FIGURE 10 - SMT 2000WCY Pump Connections Hi Pressure Interconnecting Hose Installation 12 WWW.SPRAYMASTERTECH.COM
Your system is supplied with hi-pressure interconnecting hoses of a length suitable for the location and distance of each remote station from the pump. Verify the hose length is sufficient for the location and run path to each remote station. An extra 12 18 inches of hose slack at each end will make it easier to connect and service the remote station and the pump. The control cable may be attached to the hi-pressure hose with electrical tape every few feet and pulled into place simultaneously with the hose. Leave an extra 12 18 inches or cable extending beyond the hose ends for ease of connection. A typical hose installation is to feed the hose into the area above the ceiling beginning at the pump location. Carefully pull the hose along the predetermined path to the remote station while continuing to feed the hose up into the ceiling. Take care while pulling the hi-pressure hose and cable into place that the coverings are not damaged by dragging through pinch points or against sharp edges. Feed the hose down into the wall to the location of the remote station. If a 2 PVC chase has been installed for this purpose, feed the hose and cable into it until the hose and cable exit through the opening in the wall for the remote station. Connect the hi-pressure hose to the remote station fitting using several wraps of Teflon tape on the pipe thread of the hose fitting. Connect the hi-pressure hose to the pump discharge manifold using several wraps of Teflon tape on the pipe thread of the hose fitting. Attach the hi-pressure hose to the building structure using rubber coated straps, cable-ties or equivalent hardware that will secure the hose in place while protecting the hose from damage. Anchor the hose every two to four feet. CONTROL CABLE INSTALLATION- Run the control cable with the hi-pressure hose between the remote station and the pump. Attach the cable to the hose using the cable ties provided. Connect a six-foot length of control cable into the Master Control Panel upper left corner to the 5-terminal strip using the pink crimp-on terminals shipped on the 5-terminal strip. Connect the control wires of the control cable to the appropriate terminal in accordance with the wiring diagram inside the front cover of the Master Control Panel and Figure 8 in this manual. When properly connected, all the wires connected to the terminal strip will match colors on each terminal. In the ceiling above the pump, splice all conductors in the remote station cables to the control cable from the Master Control Panel. Match color to color (black to black, red to red, etc.) Match color and connect all colored wires even though only the red, black and green conductors may be used. This will provide the option to switch to one of the other color wires should wires become damaged. Secure each wire nut connector to the wires with electrical tape. The control cable may have three to six conductor wires. If the cable is a shielded cable, splice the shield drain wires together as well. At each remote station, connect the control cable to the wire leads of the remote station key switch with the wire nuts provided, matching color to color (black to black, red to red, and green to green). Secure the wire nuts to the wiring with electrical tape. 13 WWW.SPRAYMASTERTECH.COM
MASTER CONTROL PANEL WIRING DIAGRAM FIGURE 11 - Master Control Panel Wiring Diagram 14 WWW.SPRAYMASTERTECH.COM
CONTROL CABLE SPLICING FIGURE 12 - Control Cable Splicing OPERATIONAL TIPS FOR STARTUP AND TESTING SMT2000WCY- Do not turn the key switch on without a hose and spraygun connected to the remote station. Hoses and sprayguns cannot be connected/disconnected when the system is pressurized. Squeeze the spraygun trigger to release pressure from the system BEFORE disconnection of hoses and sprayguns. If pressure is locked into the system without a spraygun connected, release pressure on the system at the pump by momentarily opening the pressure bleed valve on the pump discharge manifold. Close the pressure bleed valve immediately upon releasing the pressure. Ensure the chemical pickup tube is submersed in the chemical supply or a bucket of water to prevent pump cavitation when the remote station key switch is set to SOAP. TESTING AND OPERATION- Test and operate the system in accordance with the following instructions. Preliminary Setup Set all Key Switches at each remote station to the OFF position and remove the keys. Check the oil level. Verify the oil level is at the middle of the sight glass on the right end of the pump. Add oil as necessary but do not over-fill. Submerse the chemical pickup tube into a chemical supply. Connect a hose and spraygun to any remote station. 15 WWW.SPRAYMASTERTECH.COM
OPERATIONAL TESTING 1. Set the GFCI breaker in the facility power panel to ON. 2. Set the service disconnect at the pump to ON and verify the 24V AC indicator illuminates on the front cover of the Master Control Panel. 3. Flush the facility water supply line to remove any construction debris before connecting to the 2000WCY water supply input. 4. Turn the water supply to the unit fully open to fill the float tank and verify the Low Water indicator on the MCP illuminates.. 5. Connect a hose and spraygun to one of the untested remote stations. 6. With the hose and spraygun connected, set the Remote Station Key Switch to RINSE. The pump will turn on and the entire system will pressurize. 7. Check the system for leaks at all connections. 8. Direct the spraygun in a safe direction and squeeze the spraygun trigger. Allow the system to run until all the air is exhausted from the system. 9. Release the spraygun trigger. 10. Turn the Key Switch to OFF for three (3) seconds then turn the Switch to SOAP. 11. Direct the spraygun in a safe direction and squeeze the spraygun trigger. Allow the system to run until soap foam is observed in the spray output. 12. Turn the Key Switch to OFF for three (3) seconds then turn the Switch to RINSE. 13. Direct the spraygun in a safe direction and squeeze the spraygun trigger. Allow the system to run until the soap is purged from the system. 14. Turn the Key Switch to OFF. 15. Squeeze the spraygun trigger to release system pressure and disconnect the hose from the remote station. 16. Move the spraygun and hose to each of the untested remote stations and repeat Step 5 through Step 15. 17. After all remote stations are tested, disconnect and store all equipment in an area that is not subject to freezing temperatures. Spray Master Technologies is a quality product line of Assembled Products Corp. 115 E. Linden Rogers, Arkansas 72756 USA (479) 636-5776 Fax: (479) 636-3245 1-800-548-3373 SMT-INSTALL-2000WCY--140307 Specifications are subject to change without notice. Printed in the USA.