AIR ONE PROFILER TOP and SIDE DRYER INSTALLATION MANUAL Part # DRYRPROFLRXXXXXX (ALL COLORS)

Transcription

1 AIR ONE PROFILER TOP and SIDE DRYER INSTALLATION MANUAL Part # DRYRPROFLRXXXXXX (ALL COLORS) TABLE OF CONTENTS Equipment Specifications Page: 1 Suggested Tools and Installation Materials Page: 2 Installation Instructions Page: 2 Optional Side Profiler Page: 11 Start-Up Procedures Page: 22 Support Documents Page: 24 Equipment Specifications AIR ONE PROFILER DRYER DIMENSIONS TUNNEL LENGTH TUNNEL WIDTH UNIT HEIGHT VEHICLE CLEARANCE 64 IN (5FT-3in) 152 IN (12 FT-8 IN) 140 IN (11 FT-8 IN) 90 IN (7 FT-6 IN) ELECTRICAL PNEUMATICS TOP PROFILER ONLY MOTORS: (3, 4, 5 ) 10 HP 208/460VAC-93/42FLA-3PH TOTAL UL RECOGNIZED, CSA CERTIFIED, CE MARK, IEC IP 55 SUPPLY CONTROL: 120VAC-15AMPS UL CERTIFIED READY SIGNAL: VOLTS AC/DC 4 SCFM Equipment Features Color Skinz Snap On Structure Wrap Profile Vehicle Height for Maximum Efficiency. 10 HP Motors VAC/3 PH Premium Efficiency Very Quiet Convenient Method to Clean Inlet Strainer 3 Different Colored Molded Heavy Plastic Housing. Never Corrode, Never Fade Inverter Ready Heavy Duty Cast Steel TEFC 10 HP Motors Suggested Installation Tools and Materials Hammer Drill with 5/8 Drill Bit (8) Wedge Anchor Bolts 5/8 x 6 Sledge Hammer Safety Goggles Set of Standard Combo Wrenches Torpedo Level Measuring Tape Safety Goggles REVISION

2 Notes and safety Symbols Where necessary, important points will be highlighted in this manual, using the following symbols: NOTE: PROVIDES FURTHER INFORMATION! STOP! PRECAUTION TO AVOID EQUIPMENT MALFUNCTION OR ERROR! WARNING! DANGEROUS SITUATION WHICH MAY CAUSE EQUIPMENT DAMAGE, PERSONAL INJURIES OR FATALITIES! Always follow all Notes, Warnings and instructions. Failure to do so may have serious consequences on the overall performance of the equipment and/or the safety of the people working on the equipment! Air One Top Profiler Installation Procedures Upon receiving your MCWW equipment, open all boxes and crates and verify that you have all the required components and there is no damage to the equipment. Verify that you have all your installation materials PLEASE COMMUNICATE WITH YOUR LOCAL MOTOR CITY WASH WORKS REPRESENTATIVE FOR ANY DAMAGE TO YOUR EQUIPMENT! Remove packaging material covering the Dryer pallet and remove the two legs and bring them in the wash in the area where the dryer will be installed. The leg with the PROFILER AIR ONE DRYER air panel will be positioned on the PASSENGER S SIDE of the conveyor. Pic #1: Passenger Side Leg REVISION

3 Using the pictures #2 and 3 showing the different equipment envelopes, verify that there is sufficient room for your PROFILER dryers. 144" 64" Pic #2: Profiler Dryer Envelope 144" 8" 140" 84" 67" 90" Pic #3: Profiler Dryer Straight Configurationl Dimensions REVISION

4 Bring a fork lift to the dryer crate and position the forks under the dryer main cross beam. Secure the dryer frame using a large C-Clamp as shown in Picture #4 below. Bring the dryer to the installation area. HERE HERE LIFT Pic #4: Secure Dryer Frame with C-Clamps Chose which configuration you want your top dryer: STRAIGHT (see previous Picture #3) if installed as a first dryer coming out of the rinse area or ANGLED (see Picture #5 below). If you chose the ANGLED configuration, move the producers to the desired distance shown below, before mounting the head assembly to the legs. ENTRANCE TRAVEL Pic #5: Angled Configuration REVISION

5 Bring the dryer inside the wash bay in the area to be installed. Verify orientation: The center producer is located on the ENTRANCE SIDE. Raise the dryer frame and secure both legs on each side of the frame. Use the highest set of ½ holes to secure the legs to the cross beam (see Picture #5). Position the OUTSIDE EDGE of the DRIVER SIDE LEG 45 from the INSIDE EDGE of the INSIDE GUIDE RAIL (see Picture Below) and, if you have purchase the Profiler Top unit 72 MINIMUM (CENTRE LEG TO CENTER LEG) BEHIND THE PROFILER TOP UNIT. 113" 45" Pic #6: Level Frame Secure the frame to the floor with 8 X 5/8 x 6 WEDGE TYPE anchor bolts and level in both directions as shown in pictures #6. Locate the two photo-eye trees and install as shown in Picture #7 and #8 below. REVISION

6 P/S TREE RECEIVER P/E SECURE THE PHOTO-EYES TREE MOUNTS USING THE MIDDLE HOLES D/S TREE EMITTER P/E Pic #7: Photo-eye Trees D/S TREE P/S TREE Pic #8: Photo-eye Trees from Top REVISION

7 Locate the Control box and mount on the PASSENGER S SIDE as shown in picture #9 and 10 below. Pic #9: Control Box Mounts Pic #10: Control Box POWER CABLE SOLENOID VALVE CABLES CONTROL CABLE RECEIVER P/E CABLES NOZZLE #1 DOWN EMITTER P/E CABLES Pic #11: Control Box Cables REVISION

8 After the control box is secured properly, pull the gray EMITTER PHOTO-EYE CABLE (see Picture #11) behind the control box and then up thru the cross beam toward the driver s side and down the leg. Finally, pull each individual cable terminated at the end of the main cable and connect each one of them for each photo-eye (see picture #12). Using plastic ties, secure the cable in the cross beam as shown in picture #13. Pic #12: Photo-Eye Cable Pic #13: Plastic Ties NOTE: ANY CABLE QUICK DISCONNECT MAY GO TO ANY PHOTO-EYE. HOWEVER, THE SHORTEST ONE SHOULD GO TO THE MIDDLE THE LONGEST ONE TO THE EXIT AND THE LAST ONE TO THE ENTRANCE Pull down the two solenoid valve cables and connect to the appropriate valve Pic #14: Air Valve Cables REVISION

9 Pull the three emitter cables and pull them thru the photo-eye tree. Connect to the appropriate photo-eye: CONNECT ENTR CABLE TO ENTRANCE SIDE RECEIVER PHOTO-EYE CONNECT MIDL CABLE TO MIDDLE RECEIVER PHOTO-EYE CONNECT EXIT CABLE TO EXIT SIDE RECEIVER PHOTO-EYE Pic #15: Receiver Photo-eye Cables Pull the power and the control cable behind the box and up to the ceiling. Connect each cable in its own separate junction box. YOUR PROFILER DRYER REQUIRES A POWER SOURCE OF 120VAC. CONNECT THE POWER CABLE TO A SEPARATE 120VAC CIRCUIT. YOUR PROFILER DRYER ALSO REQUIRES A READY SIGNAL TO BRING THE NOZZLES DOWN. THE SIGNAL MAY COME FROM HE CAR WASH CONTROLLER: THE SIGNAL HAS TO BE PROGRAMMED FOR EACH CAR. THE SIGNAL CAN BE ANYTHING BETWEEN 24 TO 240VAC OR DC SIGNAL. Connect the air hose unions and y fittings at the passenger upper side corner (see Picture #16). Pic #16: Connect Air Lines REVISION

10 PNEUMATIC INSTALLATION Your Profiler Dryer requires a 3/8 air line capable of 4 SCFM. Connect the air line to the air panel inlet fitting. AIR INLET Pic #17: Air Panel Locate the boxes containing the COLOR SKINZ covers and install on each leg and photo-eye tree (see below). SELECT THE PROPER COLOR SKINZ COVER. SNAP ONE SIDE OF THE LIP, SLIDE THE COVER AROUND THE LEG AND FINALLY SNAP THE SECOND LIP PAST THE EXTRUSION EDGE (see Picture #19) Pic #18 Color Skinz Pic #19 Color Skinz Pic #20 Photo-Eye Tree Color Skinz Pic #21 Color Skinz REVISION

11 Locate the ACCENT COVERS and install as followed: 8PLASCVRXDXX0011 (15-1/2"L) (2) 8PLASEXTXXX0005 (131-3/4"L) 8PLASCVRXXX "L 8PLASCVRXXX "L (2) 8PLASCVRXDXX0052 (25"L) (2) 8PLASCVRBLK0053 (12"L) (2) 8PLASCVRXDXX0040 (41"L) (2) 8PLASCVRXDXX0052 (25"L) 8PLASCVRXDXX0012 (52-1/2"L) 8PLASCVRXDXX0012 (52-1/2"L) 8PLASCVRXDXX0043 (3-1/2"L) Pic #22 Plastic Covers Map REVISION

12 Locate the PROFILER FABRIC NOZZLES and select the nozzle with the smallest diameter, slide the opening on the producer outlet. Push a PLASTIC TIE through the seam and pull trough each of FOUR PLASTIC TIE MOUNT located on the producer outlet (see Picture #23 below). Tighten the plastic tie and push the end back into the seam (see below).do NOT CUT THE PLASTIC TIE! Repeat for the other two nozzle. Pic #23 Smaller Fabric Nozzle Locate the OUTSIDE FABRIC NOZZLES and install on the outer ring following the same method as the INSIDE NOZZLES (see Picture #24). Pic #24 Outward (Longer) Nozzle REVISION

13 Air One 40HP Side Profiler Installation Procedures: Upon receiving your MCWW equipment, open all boxes and crates and verify that you have all the required components and there is no damage to the equipment. Verify that you have all your installation materials PLEASE COMMUNICATE WITH YOUR LOCAL MOTOR CITY WASH WORKS REPRESENTATIVE FOR ANY DAMAGE TO YOUR EQUIPMENT! Remove packaging material covering the Dryer pallet and remove the two legs and bring them in the wash in the area where the dryer will be installed. The leg with the PROFILER AIR ONE DRYER air panel will be positioned on the PASSENGER S SIDE of the conveyor. Pic #25: Passenger Side Leg Using the pictures #26 and27 showing the different equipment envelopes, verify that there is sufficient room for your SIDE PROFILER dryer. 60" 194" 144" Pic #26: Side Profiler Dryer Envelope REVISION

14 144" 140" 84" 67" 90" Pic #27: Side Profiler Dryer Overall Clearance 72" MINIMUM 136" Pic #28: Envelope for Both Top and Sides Profiler REVISION

15 Bring a fork lift to the dryer crate and remove the two CENTER PRODUCERS from the frame. They will be installed on the sides at a later time. FORK 2 1 Pic #29: Remove Center Producer Position the forks under the dryer main cross beam. Secure the dryer frame using a large C-Clamp as shown in Picture #30 below. Bring the dryer to the installation area. FORK FORK LIFT Pic #30: Secure Dryer Frame with C-Clamps Bring the dryer inside the wash bay in the area to be installed. Verify orientation: The two TOP PRODUCERS are located on the ENTRANCE SIDE of the cross beam. Raise the dryer frame and secure both legs on each side of the frame. Use the highest set of ½ holes to secure the legs to the cross beam (see Picture #31). REVISION

16 1/2" FASTENERS Pic #31: Secure Dryer Legs Position the OUTSIDE EDGE of the DRIVER SIDE LEG 45 from the INSIDE EDGE of the INSIDE GUIDE RAIL (see Pictures Below). EXIT DOOR 45" Pic #32: Legs Assemblies Pic #33: Level Frame NOTE: THE SIDE PRODUCERS HAS TO BE INSTALLED WITH THE IMPELLER FACING THE EXIT OF THE WASH REVISION

17 Secure the frame to the floor with 8 X 5/8 x 6 WEDGE TYPE anchor bolts and level in both directions as shown in pictures #32 and #33. Install the SIDE PRODUCERS 89 OFF THE FINISH FLOOR ON PASSENGER SIDE and OFF THE TOP OF THE CONVEYOR ON DRIVER SIDE (see Picture #34). EXIT DOOR 89" 87 45" Pic #34: Side Producers at 89 Off the Floor NOTE: THE SIDE PRODUCERS HAS TO BE INSTALLED WITH THE IMPELLER FACING THE EXIT OF THE WASH REVISION

18 Locate the two photo-eye trees and install as shown in Picture #35. D/S TREE EMITTER P/E SECURE THE PHOTO-EYES TREE MOUNTS USING THE MIDDLE HOLES P/S TREE RECEIVER P/E Installing The Control Box: Pic #35: Photo-eye Trees Your 40HP Side Profiler dryer has the same control box than the 30HP Top Profiler Dryer (see Picture #18). After the control box is secured properly, pull the gray EMITTER PHOTO-EYE CABLE (see Picture #18) behind the control box and then up thru the cross beam toward the driver s side and down the leg. Connect TWO CABLES to the two emitter photo-eye. The third cable WILL NOT BE USED. Push the third cable into the photo-eye tree. Using plastic ties, secure the cable in the cross beam as shown in picture #37. Pic #36: Photo-Eye Cable Pic #37: Plastic Ties REVISION

19 NOTE: ANY CABLE QUICK DISCONNECT MAY GO TO ANY PHOTO-EYE. HOWEVER, THE SHORTEST ONE SHOULD GO TO THE MIDDLE THE LONGEST ONE TO THE EXIT Pull down the solenoid valve cables and connect to the valve. Pic #38: Air Valve Cables Pull the two emitter cables and pull them thru the photo-eye tree. Connect to the appropriate photo-eye: CONNECT MIDL CABLE TO MIDDLE RECEIVER PHOTO-EYE CONNECT EXIT CABLE TO EXIT SIDE RECEIVER PHOTO-EYE Pic #39: Receiver Photo-eye Cables Pull the power and the control cable behind the box and up to the ceiling. Connect each cable in its own separate junction box. REVISION

20 YOUR 40HP SIDE PROFILER DRYER REQUIRES A POWER SOURCE OF 120VAC. CONNECT THE POWER CABLE TO A SEPARATE 120VAC CIRCUIT. YOUR 40HP SIDE PROFILER DRYER ALSO REQUIRES A READY SIGNAL TO BRING THE NOZZLES DOWN. THE SIGNAL MAY COME FROM THE CAR WASH CONTROLLER. THE SIGNAL HAS TO BE PROGRAMMED FOR EACH CAR. THE SIGNAL CAN BE ANYTHING BETWEEN 24 TO 240VAC OR DC SIGNAL. BOTH SIDE AND TOP PROFILER DRYER CAN USE THE SAME READY SIGNAL PNEUMATIC INSTALLATION Your Side Profiler Dryer requires a 3/8 air line capable of 2 SCFM (6 SCFM Total for both units together). Connect the air line to the air panel inlet fitting. AIR INLET Pic #40: Air Panel Like Top Profiler unit, pull the air lines and connect to the y fittings at the passenger upper side corner (see Picture #16). REVISION

21 SIDE PRODUCERS INSTALLATION: Locate the SIDE HOUSINGS and mount on each SIDE PRODUCERS starting with the DRIVER SIDE. Install the housing with the outlet pointing down and then rotate THE HOUSING 30 COUNTER CLOCKWISE and secure in place (see Picture #41). Repeat the same procedure with the PASSENGER SIDE EXIT DOOR Pic #41: Rotate Side Housings Loosen the SIDE PRODUCER MOTOR MOUNT fasteners (See Picture #42 below) and TILT THE MOTOR TOWARD THE EXIT ABOUT 5. Repeat the same process for the other side (see Picture #43). VEHICLE DIRECTION Pic #42: Motor Mount Adjustment REVISION

22 VEHICLE DIRECTION Pic #43: Tilt Side Housings COLOR SKINZ INSTALLATION Locate the boxes containing the COLOR SKINZ covers and install on each leg and photo-eye tree (see below). SELECT THE PROPER COLOR SKINZ COVER. SNAP ONE SIDE OF THE LIP, SLIDE THE COVER AROUND THE LEG AND FINALLY SNAP THE SECOND LIP PAST THE EXTRUSION EDGE (see Picture #45) Pic #44 Color Skinz Pic #45 Color Skinz Pic #46 Photo-Eye Tree Color Skinz Pic #47 Color Skinz REVISION

23 Locate the ACCENT COVERS and install as followed: 8PLASCVRXDXX0011 (15-1/2"L) (2) 8PLASEXTXXX0005 (131-3/4"L) 8PLASCVRXXX "L 8PLASCVRXXX "L (2) 8PLASCVRXDXX0052 (25"L) (2) 8PLASCVRBLK0053 (12"L) (2) 8PLASCVRXDXX0040 (41"L) (2) 8PLASCVRXDXX0052 (25"L) 8PLASCVRXDXX0012 (52-1/2"L) 8PLASCVRXDXX0012 (52-1/2"L) 8PLASCVRXDXX0043 (3-1/2"L) Pic #48 Plastic Covers Map REVISION

24 Locate the PROFILER FABRIC NOZZLES and select the nozzle with the smallest diameter, slide the opening on the producer outlet. Push a PLASTIC TIE through the seam and pull trough each of FOUR PLASTIC TIE MOUNT located on the producer outlet (see Picture #49 below). Tighten the plastic tie and push the end back into the seam (see below).do NOT CUT THE PLASTIC TIE! Repeat for the other two nozzle. Pic #49 Outlet Producer Screws Locate the TWO OUTSIDE FABRIC NOZZLES and install on the outer ring following the same method as the INSIDE NOZZLES (see Picture #50). Pic #50 Outward Nozzle REVISION

25 When all the fabric nozzles are secured, verify that each PRODUCER ARE ANGLED AND ORIENTED LIKE SHOWN ON PICTURE # 51. Pic #51 Angle Nozzles Start Up Procedure Start each dryer, one at a time and verify for proper rotation and if any IMPELLER rubs on any INLET CONE. If an IMPELLER rubs on an INLET CONE, adjust the position of the INLET CONE by removing the 3 TOP BOLTS and the 3 BOTTOM BOLTS securing the inlet screen to the INLET CONE (see Picture#52). Pic #52: Inlet Screen Pic #53: Inlet Cone Fastener REVISION

26 Loosen the two remaining bolts holding the inlet cone (See Pic #53). Spin the impeller and adjust the inlet cone until it no longer interferes with the inlet cone. Tighten the bolts. Reinstall the inlet screen. YOUR MCWW DRYER COMES WITH TWO DIFFERENT PRODUCER/IMPELLERS CLOCKWISE (CW) AND COUNTER-CLOCKWISE (CCW) A PRODUCER HOUSING HAS TO BE INSTALLED TO THE PROPER IMPELLER. ALWAYS INSTALL CW PRODUCER HOUSING WITH CW IMPELLER ALWAYS INSTALL CCW PRODUCER HOUSING WITH CCW IMPELLER SEE PHOTO BELOW TO IDENTIFY ROTATION Pic #54: CW Impeller Pic #55: CCW Impeller Pic #56: CW Housing Pic #57: CCW Housing Turn the air supply ON and adjust both main regulator (PROFILER TOP and PROFILER SIDES to 60 PSI. Push the manual button override for each air panel valve (see Picture #58 and 59) and confirm that each nozzle are extending down when pushed. NOTE: IF ANY OF THE NOZZLE ARE COMING UP AFTER THE MANUAL OVERRIDE BUTTON IS PUSHED CROSS THE AIR LINES AT THE VALVE OR AT THE CYLINDER HOUSING (SEE PICTURE #60 AND 61) PUSH BUTTON AND ENTRANCE NOZZLE COMES DOWN NOZZLE #1 DOWN PUSH BUTTON AND ENTRANCE NOZZLES COMES DOWN NOZZLE DOWN PUSH BUTTON AND EXIT NOZZLES COMES DOWN NOZZLE #2 AND #3 DOWN SUPPLY SUPPLY Pic #58: Profiler Top Air Panel Pic #59: Profiler Side Air Panel REVISION

27 Pic #60: Profiler Top Air Cylinder Pic #61: Profiler Top Air Cylinder Pic #61: Profiler Pic #62: Profiler Pic #63: Profiler Top Air Panel Top Air Cylinders Side Air Cylinders Turn the power ON to the controllers and verify that the POWER pilot light is ON (see Picture #64). Turn ON the car wash controller OUTPUT for the READY SIGNAL and confirm that the light is ON and the NOZZLES ARE COMING DOWN. Block each photo-eye and verify that each nozzle is retracted after the photo-eye is broken. Test with a car. POWER LIGHT READY SIGNAL LIGHT Pic #64: Control Box REVISION

28 Support Documents: Pic #66: Electrical Control Box Wiring Diagram REVISION

29 Warranty and Return Procedure: Motor City Wash Works warrants this product to be free of defect in material and/or workmanship for a period of one year.. During the warranty period MCWW will at its discretion, at no charge to the customer, repair or replace this product if found defective, with a new or refurbished unit, not to include costs of removal or installation. Any product returned to MCWW for warranty has to have a Return Material Authorization Number. All shipping costs to MCWW are assumed by the customer. This is only a summary of MCWW s Limited Warranty. Please, communicate with MCWW for our complete warranty. Prior to returning any product to MCWW, the customer must call in for a Return Material Authorization Number and a copy of our Return Material Authorization Form must be completed. The RMA number must be written clearly on the outside of the shipping package and a copy of the form must be included in the package. REVISION