Installation, Operating, & Maintenance Instructions 98608000 REV-REL 1-574-295-8330 www.elkhartbrass.
Contents PRODUCT SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SYSTEM INFORMATION:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 COBRA EXM2 MONITOR FEATURE CALLOUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT SAFETY INFORMATION • All personnel who may be expected to use this equipment must be thoroughly trained in its safe and proper use. • Before flowing water from this device, check that all personnel (fire service and civilian) are out of the stream path. Also, check to make sure stream direction will not cause avoidable property damage. • Become thoroughly familiar with the hydraulic characteristics of this equipment, and the pumping system used to supply it.
COBRA EXM2 MONITOR FEATURE CALLOUTS X-Stream Series Master Stream Nozzle Double Race Bearings 2.
SYSTEM COMPONENTS MONITOR COBRA™ EXM2 Monitor – 7200X2 The COBRA™ EXM2 monitor is specially designed to be compact providing a greatly reduced swing radius. Unique waterway swivel joints utilize stainless steel thrust rods, and needle roller thrust bearings, for unprecedented durability in a range of applications. The COBRA™ EXM2 utilizes a cast vaned waterway to minimize large-scale turbulence.
CONTROL Joystick Controller - 7030X2 The Joystick Controller can be mounted inside the apparatus cab to control all monitor functions, including oscillation, stow and deploy.The monitor direction (both vertical and horizontal movement) is changed by moving the joystick in the desired direction of travel. The up-down and left-right motions can be operated simultaneously with pressure sensitive speed, moving the monitor faster or slower depending on how far the joystick is pushed and pulled.
MONITOR & VALVE ACCESSORIES Position Feedback Display – 7051X2 All EXM2 monitors come with Absolute Position Feedback sensors.These sensors provide constant feedback to the monitors’ processor even when the monitor is moved via manual override. This information is then transmitted to the Position Feedback Display. Unibody Valve with E14X or E16X Electric Actuator – The Unibody water valve provides a convenient remote on/off and preset valve positioning control of the water supply to the COBRA™ EXM2.
• CAN wire type and shielding: Twisted shielded pair - 105°C 150V (Belden 9841 series or equivalent) • Shield Drain: Connect shield/drain to pin C of J1939 connector Recommended electrical requirements for the EXM2 input devices– • Power and Ground wire gauge and length: 18-20 AWG Cross link or equivalent 105°C 150V up to 150 ft. (45.7 m) • Maximum input controller amperage draw: 500mA • CAN wire gauge and length: 3 ft.
• The monitor will use a CAN line to communicate with other EXM2 components. Connect the monitor pigtail 1 to CAN bus. • Supply power to the monitor by connecting the two red and two black leads from the 8 pin connector to an appropriate power source. Install one 20 Amp fuse in line to both positive power leads for a 12V system (10 Amp for 24V system) to protect the monitor electrical components. • Refer to the respective plug figures for information on the plugs’ pins.
Proximity Sensor for Extended Travel: An OEM supplied proximity sensor is used only for extended travel functionality and is not necessary for standard monitor operation. The Cobra EXM2 is capable of vertical extended travel beyond the calibration point (straight up). An additional ground input is needed to enable this functionality.This functionality is intended to allow an OEM supplied proximity sensor to be used to enable or disable extended travel when the monitor is used with aerial applications.
Cable B – P/N 37550000 Monitor Pigtail included with EXM2 monitor Cable C – P/N 37544000 Valve Pigtail included with E14X/E16X actuator Cable D - P/N375440NT Valve Pigtail non-terminated harness for E14X/E16X valve actuator (optional) Cable E – EXM2 Extension Cable (optional) 12
Cable F – P/N 24196000 Splitter (optional) Cable G – P/N 24197000 CAN Termination Plug (optional) Cable H – P/N 37561000 Docking Station Pigtail included with EXM2 Hand Held pkg Cable J - P/N37551000 Gateway Pigtail included with EXM2 Hand Held pkg 13
EXM2 Wiring Connections E E E F CAN Splitter E F CAN Splitter F CAN Splitter C B EXM2 Monitor A 7051X2 EXM2 Position Feedback Module A Terminating Resister A 7010X2 EXM2 Panel Mount or 7030X2 EXM2 Joystick Controller (Both Factory Set as Primary) E14X/E16X Actuated Valve EXM2 Gateway EXM2 Handheld Controller and Docking Station 7015X2 EXM2 Handheld Package (Factory Set as Secondary) Valve comes terminated from factory EXM2 monitors come terminated from factory and should always be at end
Handheld Controller, Gateway and Docking Station – • Using the Docking Station template located at www. elkhartbrass.com, drill 6 #7(0.201” 5.1mm) drill holes shown through the panel intended to hold the Panel Mount. • Mount the Docking with six (6) 10-24 screws using blue Loctite 242 or equivalent. The controller has a 0.375 thread depth. Torque screws to 50-60 in-lbs (5.6-6.8 Nm). • Supply power to the Docking Station by connecting the plug leads shown to an appropriate unswitched power source.
Joystick Controller – • Using the Joystick Controller template located at www. elkhartbrass.com, drill all holes shown through the panel intended for mounting the Joystick Controller. • Mount the Joystick Controller using 4 3/8” fasteners secured with blue Loctite 242 or equivalent. • If the Joystick/OEM will use CAN communication, connect the green, black, and yellow leads coming from plug 1 to the appropriate CAN line.
Position Feedback Display – • Using the Position Display template located at www.elkhartbrass. com, drill the two 11/64” holes shown through the panel intended for mounting the display. • Mount the Position Feedback Display using two (2) 6-32 x ½” fasteners secured with blue Loctite 242 or equivalent. Torque to 50-60 in-lbs (5.6-6.8 Nm). • Connect leads to the appropriate CAN line. • Supply power to the Position Feedback Display by connecting plug 1 leads to an appropriate power source.
Nozzles – • Ensure there is a gasket inside the nozzle swivel. • Hand tighten the nozzle onto the monitor discharge. • Loosen the swivel to reposition the nozzle as shown. • Tighten the nozzle swivel with a spanner wrench. • Supply power to the nozzle by connecting the monitor and nozzle two-way connectors.
Installation Step 2: Configure the EXM2 System NOTE: EXM2 systems using CAN communication and consisting of a monitor and one controller (panel mount or Joystick) do not require configuration. EXM2 monitors come factory set for CAN termination. A position feedback display can also be used without the need for configuration; as long as it is connected to the main CAN line between the monitor & controller.The monitor must be at the extreme end of the main CAN line to provide CAN termination.
• Changes made will not take effect until after exiting Setup Mode. Setup Mode will automatically be exited after five minutes of no user inputs. ! Caution: There are no vertical or horizontal travel limits when in Setup Mode. MOVE THE MONITOR WITH CAUTION WHILE IN THIS MODE. If monitor is obstructed by an object or by itself, the motors may over current and need to be moved manually out of the interfering object’s way.
Calibrate Valve NOTE: LEDs flashing above the closed & open buttons on an input controller indicate that the valve has not been calibrated. If an Elkhart Brass Unibody valve is being used in your system, calibrate it at this time by first placing the valve in a half open position, and then pressing and holding the CLOSE and PRESET buttons on any controller until the valve calibration begins.
OPERATING INSTRUCTIONS A. Button / Joystick Operation • POWER – Turns Hand Held controller on and off.
C. Re-calibrating Horizontal and Vertical Rotation Calibrating the EXM2 system’s horizontal and vertical rotation is a necessary step for EXM2 systems of all types. The calibration points serve as a starting point for all other motion limits and commands entered to the EXM2 system. If not properly calibrated, the system may not operate correctly.
Proximity Switch Input Vertical Max (Degrees) Vertical Min(Degrees) Ground +120° -45° Open Circuit +90° -45° The extended travel function will only work if the monitor is properly vertically calibrated (see Installation Step 3) and if the highest vertical travel limit is properly set (see Operation Instructions D). • The vertical Calibration Point will become the highest point of operation when the proximity switch is in Open Circuit (extended travel disabled).
Figure 1: Keep-Out Zones G. Stow Position The Stow Position is a preset position that can be used to bring the monitor into a position suitable for when the system is powered off. A stow position must be within the allowed travel area defined by any travel limits or keep-out zones, therefore it is recommended that travel limits and keep-out zones are set before setting a stow position. ! Warning! Water SHOULD NOT be flowing while stowing the monitor. H.
• Put the EXM2 system into Setup Mode (reference Part B of the Operating Instructions section). • Press the OPEN and CLOSE buttons simultaneously. • All set Travel Limits, Keep-Out Zones, and Stow Positions will be removed from the system. J. Oscillation The oscillation function is used to move the monitor back and forth inside a boxed area or straight horizontal or vertical line specified by the user.
MAINTENANCE INSTRUCTIONS Preventive Maintenance The complete monitor and control system should be inspected during each apparatus check. Careful inspection for damage to the monitor, valve or nozzle is especially important after use of the COBRA™ EXM2 monitor in emergency operations.
TROUBLESHOOTING GUIDE Understanding System LEDs Monitor Controller LEDs • Normal Operation • When the monitor is first powered up all LEDs turn on for approximately 1 second, then only the Power LED remains illuminated • When the monitor control box powers the horizontal motor, the RIGHT-LEFT LED illuminates. (The box may power the motor if it receives a right or left command, a stow/deploy command, etc.) • When the monitor control box powers the vertical motor, the UP-DOWN LED illuminates.
• DEPLOY LED • Lit solid = monitor has been deployed and is now at its deploy position. • Flash = monitor is moving to its deploy position • CLOSE LED • LEDs flashing above both the open & close buttons indicate that the valve needs to be calibrated. • Lit solid = valve is in the fully-closed position (unless the user brings the system into Setup or Programming Modes). • Flash = valve is closing (whether in auto-travel mode or while holding the CLOSE button).
pattern if an error occurred that caused the monitor to report a significant Diagnostic Trouble Code and go into safe mode. (The reported error is described through the EXM2 web interface accessed over Wi-Fi.) The blink pattern indicates the condition. The blinks will continue until the panel mount is reset (power-cycled). The blink pattern is as follows: Status Blink Pattern Reason for Safe Mode 2 blinks continuous Not Calibrated 3 blinks continuous Sensor Failure 4 blinks continuous.
Status Blink Pattern Reason for Safe Mode 2 blinks continuous Not Calibrated 3 blinks continuous Sensor Failure 4 blinks continuous. Sensor indicates that monitor is moving in the opposite direction of the expected. 5 blinks continuous Sensor did not detect movement on motor when power was applied to either vertical or horizontal motors. 6 blinks continuous During movement of the monitor, the monitor’s input voltage dropped below 10 VDC.
• Blink meanings: • Green, Blue, or yellow blinking in a regular pattern (50% duty cycle) indicates at least one of the following: • the monitor is moving • valve is moving • a button is being pushed on this panel mount. • When not moving or pushing buttons with Wi-Fi off, the STATUS LED blinks a yellow pattern if an error occurred that caused the monitor to report a significant Diagnostic Trouble Code and go into safe mode.
SYSTEM SPECIFICATIONS 7200 EXM2 Monitor Max Flow Rating 1250 GPM (4731 LPM) Max Operating Pressure 250 PSI Continuous (17.2 BAR) 500 PSI Limited Duty (34.5 BAR) [50% / 1hr (30min on / 30 min off)] Inlet Size 3”-150# Flange, DN80-PN16 Flange, 4”-150# Flange, 3” NPT, 3” BSPT Outlet Size 2.5” Male NHT, 2.5” Male BSPP Travel V: -45° to +120°, H: L175° to R175° Movement Sealed Electric Motors Swing Radius 6” (152mm) Stow Height 16” (406mm) Weight 31 Lbs.
Handheld Controller - 7015X2 Input power Li-Ion 3.7V Battery Life 3 years Battery Charge Life Up to 24 hours operation before recharge required RF Power Output Meets FCC part 15 requirements for license free operation (See note on page 33) Controller Dimensions 7.54in(191.5mm) x 3.85in(97.8mm) X 2.38in(60.5mm) Controller Weight 1.3 lbs.(0.
Gateway Handheld Model: 7015X2GW Model: 7015X2 FCC ID: QT8EXM2GW FCC ID: QT8EXM2WH FCC Statement: FCC Statement: Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules.
Elkhart Brass Manufacturing Co., Inc. 1302 W. Beardsley Avenue Elkhart, IN 46514 Tel. (574) 295-8330 Toll Free (800) 346-0250 Fax (574) 293-9914 www.elkhartbrass.com Email: eb.info@safefleet.