Article ID: KB20240606-ARM4

Date: June 6, 2024

Author: Keith Bunch

Introduction

Welcome to the ARMOR 4 upgrade installation guide. This document is designed to assist technicians in upgrading Kaivac cleaning machines from ARMOR 2 or ARMOR 2+ systems to the new ARMOR 4 system. This upgrade simplifies the electrical system by eliminating the voltage step-down and "Y-Cable-Box."

Applicability

• Applicable Models: Most Kaivac machines (Blue) originally equipped with ARMOR 2.
• Exception: Green Kaivac machines (17cc) that come with ARMOR 2+ installed.

Kit Contents

• ARMOR 4 module with an IP67 5-wire harness
  • Works on 9V to 90V
• New IMEI sticker
• ARMOR 5-wire OEM cable
• WAGO connectors (Four 3-way)
• Installation instructions (sheet or QR code)

Installation Instructions

1. Preparation

   • Check in with management before starting the upgrade.
   • Locate the Blue Kaivac 17501 machine, typically stored in the janitor's closet.
   • Ensure the machine's 36V lithium battery is charged and connected.
   • Empty the waste and clear water tanks using the vacuum hose for efficiency.

2. Disassembly

   • Open the black box where the ARMOR 2 is located.
   • Remove the inner shield to access the components.

3. Removing Old Components

   • Disconnect and remove the voltage step-down module and the "Y-Cable-Box".
     • Step-Down Module - Two (36V) wires in, Two (12V) wires out
     • Y Cable Box - Two red motor wires in, one red digital wire out

4. Installing ARMOR 4

   • Connect the new 5-wire ARMOR 4 harness as follows:
     • Ground Connection: Connect the main battery negative to the ARMOR's green ground wire using a 3-way WAGO connector.
     • Power Connection: Connect the main battery positive to the ARMOR's orange positive wire using a 3-way WAGO connector.
     • Motor Connections: Replace the old Y-cables with direct connections from the ARMOR 4 harness to the motors. Use the yellow wire for one motor and the red wire for another.

5. Finalizing Installation

   • Secure the ARMOR 4 module inside the black box.
   • Connect and ensure the ARMOR 4 is powered on, indicated by flashing green and red LED lights on the module.

6. Testing and Verification

   • Test the installation by visiting https://check.armordata.io to verify connectivity and functionality.
   • Run the vacuum motor for 2 minutes and check for proper operation.

7. Reassembly and Documentation

   • Reassemble the Blue Kaivac machine.
   • Apply the new IMEI sticker over the old IMEI sticker on the side of the black box.
   • Document the upgrade by taking a photo of the new IMEI sticker alongside the machine's serial number.
   • Send the photo to [email protected] and attach it to your work ticket.

Additional Resources

• For visual assistance, watch the included video demonstration for “ARMOR 4 upgrade installation.”

This guide ensures a seamless transition to the ARMOR 4 system, enhancing machine performance and simplifying maintenance.