aqua-lab hd/xd - hydra-flex, inc....aqua-lab hd/xd (wall mount) 1. drill (4) 5/32” holes on the...
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© Hydra-Flex, Inc. 2017 Page | 1
AQUA-LAB HD/XD™CHEMICAL DISPENSING SYSTEM
User ManualREV F
4000087 revF0917© Hydra-Flex, Inc. 2017
© Hydra-Flex, Inc. 2017 Page | 2
TABLE OF CONTENTS
FOR ADDITIONAL SUPPORT CALL952-808-3640
OR VISIT US ON THE WEBwww.hydraflexinc.com
Specifications 3
LayoutDrawing 4
PanelDiagram 5
EstimatedInstallationTimeline 6
InstallationInstructions 6
ElectricalConnections 7
HFIBoosterPump&MCU 8ComponentDiagram 9WiringDiagram 10StartUpInstructions 12
HFIGrundfosPump&VariableFrequencyDrive(VFD) 14ComponentDiagram 14WiringDiagram 15StartUpInstructions 17
Appendix 19InitialInjectorSetup 19TripleFoamSetup 19OptimizingTheSystem 20NozzleSetup 20ChemicalUsageMeasuring 21RecommendedMaintenance 22AirOperatedValveReplacement 22BAMValveReplacement 22Troubleshooting 23
PumpIssues 23InjectorIssues 23PressureRegulatorIssues 24Flow/Archissues 24ValveIssues 24VFDIssues 24
InjectorOptimizationTool 25InjectorVacuumCheck 26HighTempShutdownRestartInstructions 26Chem-FlexInjectors-ChemicalDilutionRatios 27RecommendedSetupStartingPoints 27Chem-FlexInjectorPartNumbers 28PressureLossInRunLength 29Aqua-LabAccessories 31Aqua-LabPanelPartsDiagram 32Aqua-LabPumpPartsDiagram 34Aqua-LabControlPartsDiagram 35Aqua-LabWarranty 36
© Hydra-Flex, Inc. 2017 Page | 3
SPECIFICATIONSSPECIFICATIONS
*Recommended for use with 30A breaker.
POWER REQUIREMENTS20 GPM (75 LPM) 3 HP
Booster Pump20 GPM (75 LPM) 5 HP
Grundfos Pump40 GPM (150 LPM) 7.5 HP
Grundfos Pump Air-Actuated Valves
230V/3PH/60Hz/8.9A460V/3PH/60Hz/4.2A
230V/3PH/60Hz/12.2A460V/3PH/60Hz/5.6A
230V/3PH/60Hz/18.6A*460V/3PH/60Hz/8.9A
24 VAC, 24 VDC, or 120VAC,3.5 Watts/Port
WATER INLET LINES20 GPM (75 LPM) Booster Pump 20 GPM (75 LPM) Grundfos Pump 40 GPM (150 LPM) Grundfos Pump
1” ID 1.25” ID 2” ID
SPACE REQUIREMENTS FOR MCU, VFD, & MD PANELS (DEPTH X WIDTH X HEIGHT)
Motor Control Unit VFD HD/XD Panels
9” x 14” x 15”(23 x 36 x 38 cm)
14” x 21” x 20”(36 x 54 x 51 cm)
7” x 32” x 34”(21 x 69 x 110 cm)
SPACE REQUIREMENTS GRUNDFOS PUMPS(DEPTH X WIDTH X HEIGHT)
20 GPM Grundfos Pumps 40 GPM Grundfos Pumps
17” x 14” x 41”(44 x 36 x 104 cm)
19” x 15” x 42”(49 x 38 x 107 cm)
SPACE REQUIREMENTS WALL-MOUNTED BOOSTER PUMPS (DEPTH X WIDTH X HEIGHT)
1-PumpWall-Mount
2-PumpWall-Mount
3-PumpWall-Mount
12” x 24” x 48”(31 x 61 x 122 cm)
12” x 24” x 48”(31 x 61 x 122 cm)
12” x 36” x 48”(31 x 91 x 122 cm)
SPACE REQUIREMENTS FLOOR-MOUNTED BOOSTER PUMPS (DEPTH X WIDTH X HEIGHT)
1-PumpFloor-Mount
2-PumpFloor-Mount
3-PumpFloor-Mount
12” x 24” x 54”(31 x 61 x 138 cm)
12” x 32” x 54”(31 x 82 x 138 cm)
22” x 32” x 54”(56 x 82 x 138 cm)
OPERATING WATER PRESSURE200 PSI (14 bar) Factory Set
(Assumes 40 PSI (2.8 bar) City Feed)
MAX. WATER SOURCE TEMP.Recommended 110°F (43°C) Max water temp 137°F (58°C)
AIR INLET LINE3/8” OD Polyflow per Panel
WATER FILTRATION (SUGGESTED)
50 Micron
AIR OUTLET LINE3/8” OD Polyflow per Application
AIR INLET PRESSURE20 CFM @ 80-120 PSI (5.5-8.3 bar) Dry Air
*Assuming line length is 50’ (15 m) or less. Refer to user page 28 for recommended size chart for other lengths.
SOLUTION OUTLET LINESUp to 2.25 GPM (8.5 LPM) 3.25 - 4.5 GPM (13.3 - 17 LPM) 5.5 GPM (20.8 LPM) 10.0 - 15.0 GPM (37.9 - 56.8 LPM)
3/8” ID (1/2” OD Polyflow*) 1/2” ID* 5/8” ID* 3/4” ID
OUTLET CONNECTION FROM MANIFOLD20 GPM VERTICAL GRUNDFOS PUMP 40 GPM VERTICAL GRUNDFOS PUMP
.5” FNPT 1” FNPT
WATER SUPPLY MAX FLOW PER PORTMax Flow Per Hydra-Cannon Port 6 GPM
Max Flow Per BAM Port 15 GPM
FLANGE TORQUE20 or 40 GPM VERTICAL GRUNDFOS PUMP
37-44 ft-lbs
PRESSURE TRANSDUCER (VFD)
Pressure Range 0-300 PSI
Set point 200 PSI
Cord Length 7 Meter
© Hydra-Flex, Inc. 2017 Page | 4
LAYOUT DRAWING
***Pump configuration will vary depending on specific order options.
18.8
19.7
29.1
32.7
41.3 APPROX32 - 36"
PUMP INLET HOSE INCLUDED40 GPM: 2" HOSE INLETPROVIDED20 GPM: 1.25" HOSE INLETPROVIDED
1” x 6' QUICK CHANGEFLEXIBLE HOSE WITHREGULATOR AND WYE-STRAINER TO AQUALAB WITH 1" QUICKCONNECT AND BALL VALVEINCLUDED WITH EACHPANEL
AQUA LAB XDPANEL
1x 8ft 230V / 480VPUMP POWER CORDINCLUDED WITH EACHPUMP
PUMP STANDLOCATED WITHIN 5' OFEACH HD/XD BOARD
SIGNAL CONTROLCABLE INCLUDED
PRIMARY AIRREGULATOR3/8" POLY FLOWAIR INLET TUBINGPROVIDED BY OTHERS(100 PSI MAX)
4x TAPCON ANCHORSINCLUDED FOREACH HD/XD PANEL
VFD BOXLOCATED WITHIN 6' OFPUMP MOTORAQUA LAB 3 PHASE480V OR 230VPOWER IN PROVIDED BY OTHERS
3x 20' SIGNAL WIRETO AQUA LABINCLUDED
4X 3/8 CONCRETEANCHORS INCLUDEDWITH EACH PUMP STAND
WYE STRAINERINTEGRATED INTO OULET MANIFOLD
PRESSURE TRANSDUCERCABLE 10 FT
40 GPM: 2"NPT HOSE BARB TOCONNECT TO WATER FEED20 GPM: 1.25" NPT HOSE BARB TOCONNECT TO WATERFEED
PRESSURETRANSDUCER CABLE
POWER FROM WALL
POWER TO PUMP
18.8
41.3
16.4
40.3
20 GPMPUMP
40 GPM PUMP
19.7
19.7 20.9
18.1 12.2
VFD BOX
NOTE: MOUNT 32"FOR EASY ACCESS
© Hydra-Flex, Inc. 2017 Page | 5
PANEL DIAGRAM
Air Ports
Air Ports
Individual Air Regulators
Individual Air Regulators
Hydra-Cannon Manifold
BAM Manifold
Primary Air Regulator
Primary Air Regulator
M12 Junction Block
M12 Junction Block
Home Run Cable (Goes to car wash controller for control voltage)
Home Run Cable (Goes to car wash controller for control voltage)
Gray M12 Cable (Goes to MCU/VFD)
Gray M12 Cable (Goes to MCU/VFD)
BAM Valve
BAM Valve
Triple Foam Manifold
Triple Foam Manifold
Solenoid ActuatedAir Valves
Solenoid ActuatedAir Valves
1
1
2
2
3
3
4
4
5
5
6
6
7A
7A
7B
7B
7C
7C
© Hydra-Flex, Inc. 2017 Page | 6
WHO TASK EST. TIME
DISTRIBUTOR MONITOR&RECORDPERFORMANCE 2HR/WK
DISTRIBUTOR MAINTENANCEPERSCHEDULEORASNEEDED
POST INSTALLATION
TOTAL HOURS SPENT
INSTALLATION
TOTAL CUSTOMER 1 HR
TOTAL DISTRIBUTOR/TECHNICIAN 15 HR
TOTAL ELECTRICIAN 4 HR
TOTAL PLUMBER 4 HR
PRE-INSTALLATION
ESTIMATED INSTALLATION TIMELINE
WHO TASK EST. TIME
DISTRIBUTOR&CUSTOMER DETERMINELOCATIONTOINSTALLEQUIPMENT 1 HR
PLUMBER INSTALLWATERSUPPLYLINE 4 HR
ELECTRICIAN INSTALLELECTRICALSUPPLYLINE 4 HR
TECHNICIAN LABEL ALL CONTROLLER RELAYS AT CONTROLLER 1 HR
TECHNICIAN RUNSOLUTIONANDAIRLINES(IFNECESSARY) 5HR
TECHNICIAN INSTALLAIRSUPPLYLINE 1 HR
TOTAL LABOR HOURS 16 HRS
WHO TASK EST. TIME
DISTRIBUTOR/TECHNICIAN HANGEQUIPMENT 1 HR
TECHNICIAN CONNECTWATER,AIRANDSOLUTIONLINES 1 HR
TECHNICIAN CONNECTCONTROLLEADSTOMAINCONTROLLERORJUNCTIONBOX 2 HR
DISTRIBUTOR/TECHNICIAN STARTUP(INJECTOR,METERINGTIPANDNOZZLESELECTION) 3HR
DISTRIBUTOR/TECHNICIAN DOCUMENTCONFIGURATION 1 HR
TOTAL LABOR HOURS 8 HRS
InstallationtakesapproximatelyONEday.Anelectricianandaplumberareneededforhalfaday.
General Skill Level• Mechanical:Basic-mountingequipment• Electrical:Advanced-threephasepowerandcontrolsknowledge(localcodesknowledgerequired)• Plumbing:Moderate-principalsupplylinerequired• Pneumatic:Basic-pneumaticutilityconnectionrequired• ChemicalKnowledge:Moderate-chemicaltitrationsrequired
INSTALLATION INSTRUCTIONS
• Hammer
• Tapemeasure
• Level
• Utilityknife
• Wirestripper
• Socketset
• Adjustablewrench
• Screwdriverset
• Teflontape
Tools & Equipment Needed:• DrillwithPhillipshead
• Concretedrillbit3/8”
• Concretedrillbit5/32”
Useful Tools:• AmpMeter
• VoltMeter
© Hydra-Flex, Inc. 2017 Page | 7
UNPACKINGWhenunpackingyourAqua-LabHD/XDbesurenottodiscardthemanualoranyaccessories.Inspecttheshipmentforanydamageormissingcomponents.Ifpumpsareincludedwithorder,takecaremovingthepump(s).Utilizeproperliftingtechniqueandmechanicalassistanceifnecessary.
LOCATION & MOUNTING **IflocationwasnotidentifiedduringthePre-InstallationProcess,makesuretoconsidertheproximitytofeedwater,powersupply,andthecontrolcabinetaswellasspacenearthesystemtostorechemicalcontainers.Mountbaseofpanel32”fromfloorforeasyinjectoraccess.
***See drawing in reference for general layout
AQUA-LAB HD/XD (WALL MOUNT)1. Drill(4)5/32”holesonthewall.163/8”wide,275/8”tall.
2. PressAqua-LabHD/XDboardtightagainstthewall.
3. Screwin3/16”concretescrewswithawasher.
SYSTEMS WITH BOOSTER PUMPS & MCU PUMP ASSEMBLY - NEED TO BE WITHIN 6’ OF FURTHEST AQUA-LAB HD/XD PANEL1. Drill3/8”holesinwallforbottomslots(20”oncenterpumpnosedown,
3.5”oncenterpumpnosesideways-dualstand).
2. Insertconcreteanchors,setpumponboltsandtightendown.
3. Holdpumpstandinplace,drilltopholes,insertanchorsandtighten.
MOTOR STARTER1. Mounttothewallwith4appropriateanchors.
SYSTEMS WITH VFD & GRUNDFOS PUMPS1. Before bolting components down, ensure the water lines, electrical
cables, etc. have enough length to connect.
2. Removepumpfrompackaging.
3. Locatepumpindesiredlocation.
4. Securelyanchorpumptoconcretefloor.
5. MountVFDtothewall.
PNUMATIC CONNECTIONS• Connectpre-run3/8”ODpolyfeedlinetopushconnectfittingonthe
sideoftheprimaryregulator.
• Connect3/8”ODpolylinesfromarchtoeachportthatwillbefoaming.
**If there are unused air ports, counter-clockwise turn the individual line regulator until air no longer flows.
© Hydra-Flex, Inc. 2017 Page | 8
7 PORT AQUA-LAB (NON-HFI MOTOR CONTROL UNIT)
Make sure all VIOLET wires are separately capped with wire nuts so that they do not touch any other electrical conductive objects (One Wire Per Nut!).
7 PORT AQUA-LAB (HFI MCU STARTER/VFD)
Make sure all BLUE wires are separately capped with wire nuts so that they do not touch any other electrical conductive objects (One Wire Per Nut!).
ELECTRICAL CONNECTIONS (HFI MOTOR CONTROL UNIT)a. Wire homerun control cables to car wash control panel. (See diagram on page 16 for wiring schematic)
• Manifold position below designates which Hydra-Cannon port is associated to what color wire.• Example: if you want Presoak 1 to be on manifold port 2, connect the green wire to your
controller relay for Presoak 1.
© Hydra-Flex, Inc. 2017 Page | 9
HFI BOOSTER PUMP & MCU(SINGLE SOURCE / SINGLE PUMP SHOWN)
Timer Relay
Contactor
Thermal Overload
Temperature Shutdown Relay
Current Switch3 Phase Disconnect
Quick Connect Pump Plug Female
Grey M12 Cables (Carry signal from M12 distribution block to motor starter that turns on the pump)
FOR PART NUMBERS & DIAGRAMS - SEE PAGES 34-35
HFI BOOSTER PUMP SECTION
Wye-Strainer
Pump Outlet Feed Line To MD Panels
Bypass Pressure Regulator
Back-up Pump
Temperature Switch
Quick Connect 9’ Cordset For Pump (Plugs Into Bottom Of Motor Starter)
© Hydra-Flex, Inc. 2017 Page | 10
NOT3T2T1
NOL3L2L1
A2A1
Contacter
95
T3T2T1
989796
ThermalOverload A21816
15B1A1
TimerRelay
1 1TS1
TS2 3 3 2 2
2T1/
1
4T2/
1
6T3/
1
PE
1L1 3L2 5L3
2T1 4T2 6T3
CurrentSwitch
From BreakerFrom GreyM12 Cables(Port 6 on M12 Block)
To Temp Switch To Pump Through Power Fast Quick Connect
3 Phase
Disconect
V+
Valve
Sig
nal
V-
Jumper Jumper
JumperJumper
3 Phase
Control Voltage
Light
Relay
Switch
MCU WIRING DIAGRAM(SINGLE SOURCE SINGLE PUMP)
HFI BOOSTER PUMP SECTION
© Hydra-Flex, Inc. 2017 Page | 11
NO
T3T2
T1
NO
L3L2
L1
A2
A1Contacter
95
T3T2
T1
9897
96
Thermal
Overload
NO
T3T2
T1
NO
L3L2
L1
A2
A1Contacter
95
T3T2
T1
9897
96
Thermal
Overload
A2
1816
15B
1A
1Timer
Relay
A2
1816
15B
1A
1Timer
Relay
CB1/BLU
CB2/BLU
CB3/BLU
CB1/BLK
CB2/BLK
CB3/BLK
2T1/1
4T2/1
6T3/1
PE
TS2
TS3
CB1/BRN1
1
1
3
3
3
2
2
2
CB2/BRN
CB3/BRN
TS1
2T2/1
4T2/2
6T3/2
1L13L2
5L3
2T14T2
6T3
DCCurrentSensor
From
Grey M
12 Cab
les
To Tem
pSw
itch 1To
Temp
Switch 2
3 Phase
Disconect
DCCurrentSensor
NO
T3T2
T1
NO
L3L2
L1
A2
A1Contacter
95
T3T2
T1
9897
96
Thermal
Overload
NO
T3T2
T1
NO
L3L2
L1
A2
A1Contacter
95
T3T2
T1
9897
96
Thermal
Overload
A2
1816
15B
1A
1Timer
Relay
A2
1816
15B
1A
1Timer
RelayCB1/BLU
CB2/BLU
CB3/BLU
CB1/BLK
CB2/BLK
CB3/BLK
2T1/1
4T2/1
6T3/1
PE
TEMP1
TEMP2
CB1/BRN
CB2/BRN
CB3/BRN
2T2/1
4T2/2
6T3/2
1L13L2
5L3
2T14T2
6T3
DCCurrentSwitch
From
Breaker
To Pum
p Thro
ugh Po
wer Fast Q
uick Co
nnect
3 Phase
Disconect
DCCurrentSwitch
Jump
erJum
per
Jump
er
V-V-V-
V+
V-
Valve Signal
Valve Signal 2
Light
Relay 1
Switch 1
Light
Relay 2
Switch 2
3 PHA
SECO
NTRO
L VOLTA
GE
MULTI-SOURCE / DUAL PUMPHFI BOOSTER PUMP SECTION
© Hydra-Flex, Inc. 2017 Page | 12
FEED WATER CONNECTION**PRIOR TO CONNECTION, ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES
• Connectpre-runmainwatersupplylinetopumpinletwithhosesupplied.
• Singleoperatingpump:1”MNPT
• Dualoperatingpump:1-1/2”MNPT
START UP BOOSTER PUMPS
PUMP MUST BE PRIMED BEFORE OPERATION!WARNING!
1. FLUSHMakesurewatersupplytopumpisturnedon.Openball
valveanddirecttowardadrainorcontainertoremovethe
majorityoftheairfromthepumpuntilasteadystreamof
waterisflowing(approx. 1 min).Thenclosetheballvalve.
2. CHECK ROTATION OpenAqua-Lab™MotorControlUnit(MCU)andensure
3phasedisconnectison.(Note: Door will not open with
disconnect on. Use a 1/4” wrench or crescent wrench to turn
it back on after opening door.) (MCU with blue and black
Eaton disconnect can be opened without shutting off by
depressing button under switch handle. Press small button
with screw driver to bypass disconnect (Image 1).
!WARNING! - ELECTRIC SHOCK HAZARD. HIGH
VOLTAGE PRESENT INSIDE MOTOR CONTROL UNIT -
USE CAUTION!
Startthepumpmomentarilybydepressingthecenterofthecontactor(image 2).
a. Connect Powerfast Cordset on motor(s) to motor control unit.b. In the lower left of the enclosure, wire each leg of the incoming power to the terminals labeled 2T1, 4T2, and 6T3.
• Make sure to follow all applicable electrical codes.
c. Quick connect high temp shutdown switch.• Connect the high temp switch from the pump
assembly to MCU.
Image 1
Image 2
HFI BOOSTER PUMP SECTION
© Hydra-Flex, Inc. 2017 Page | 13
Image 5
Image 6Image 7
!WARNING! RUNNING THE PUMP BACKWARD WILL CAUSE CATASTROPHIC SYSTEM FAILURE! ENSURE THAT PUMP ROTATION IS CORRECT (image 3) asindicatedbythearrowonthecastingofthepumpandthat200psicanbereached.
• If pump cannot regulate to 200 psi, remove pump motor cover and look at shaft to confirm correct rotation.
• Verify pump inlet pressure remains positive when running.
3. CLOSE CABINET Turnon3phasedisconnect,ifhightempswitchispresent,pushtostart(Image 4).
4. PURGE BYPASSStartthepumpandslowlyopenballvalveuntilitiswideopen.Allowtorunfor60secondstoflushlinesandthenclosevalve.
5. CONNECT Connectthepumpoutletlinetothemanifoldandopenballvalve.
6. DOUBLE CHECKConfirmthatthepumpcanobtain200psiwhilefiringsolenoidsandthatthepumphousing(stainless steel tube)iscooltothetouchafteraminuteinoperation.
• If housing is hot or noisy, pump did not prime correctly.
• If pump does not prime, repeat steps 3-5.
• If not at 200 psi and the pump is correctly rotating you may need to adjust the bypass regulator to obtain 200 psi (Image 5).
Verifypumpprime24hoursafteroperationtoensureprimeheld.Paycloseattentiontothetemperatureofthepumpshaft,thewholestainlesssteelarea (Image 6)shouldbethesametemperature.Ifitstartsgettinghotterthanthesupplywaterorgreaterthan137°,thenitislikelythatthepumpdidnotprimecorrectlywhichWILL CAUSE DAMAGE TO PUMPS.Themotorhousing(paintedportion)willbehotduringoperation.
HFI BOOSTER PUMPHFI BOOSTER PUMP SECTION
******************(HFI supplied motor starter)******************
b. Connect the gray M12 cables hanging out of the motor starter box to port 8 “PUMP” on the black M12 junction boxes.
i. If you have more panels than gray wires from the MCU, connect the lose gray wires sent in the shipment into the same jumpers as the pre-wired gray cables. (This step must be completed for unit to function.)
c. Connect Powerfast Cordset on pump motor(s) to motor starter box.d. In the lower left of the enclosure, wire each leg of the incoming power to the terminals labeled 2T1, 4T2, and 6T3.
• Make sure to follow all applicable electrical codes.
© Hydra-Flex, Inc. 2017 Page | 14
HFI GRUNDFOS PUMP & VARIABLE FREQUENCY DRIVE (VFD)
Pump Power Cord, To Be Wired To VFD
Fan Fuses & Transformer
Fan Filter
Current Switch
VFD
M12 Connections To Junction Block
Gray Cord For Pressure Transducer
Motor Stool For Lifting
Pump Motor
Main Power Fuses
Fan
Incoming Power
ElectricDisconnect
Location For Pressure Transducer,
Temp Switch, Pressure Gauge.
(QTY 3: 1/4” FNPT)
Vent Cap To Prime pump
Embossed Arrow For Motor Direction
Pump Inlet (1.25” ID Hose For 20 GPM, 2” ID Hose For 40 GPM)
Pump Outlet (1/2” FNPT for 20 GPM, 1”
FNPT For 40 GPM)
Wye Strainer Screen (Inside Manifold,
Remove Plug To Clean Strainer Screen)
HFI GRUNDFOS PUMP SECTION
FOR PART NUMBERS & DIAGRAMS - SEE PAGES 34-35
© Hydra-Flex, Inc. 2017 Page | 15
S+S-
S+S+
S-S-
Jum
per
Jum
per
NCNCNC
OVOV
24V24V
204217
Jum
per
Ground
Jum
per
Curre
ntSw
itch
MAI
NSU1
W1
V1M
OTO
RU2
W2
V21
23
45
67
8
910
1112
1314
1516
Bloc
k 1Bl
ock 2
Powe
rFr
om F
uses
24 -
12 =
Cur
rent
Swi
tch
24 -
217
= Pr
essu
re T
rans
duce
r
24 -
204
= Te
mp
Switc
h or
Jum
per
Pum
p
Cap
Brow
n W
ire
Tran
sduc
er: B
rown
= 2
4VBl
ue =
217
Shiel
d =
Gree
n
Aqua
-Lab
Pane
l 1Aq
ua-L
abPa
nel 2
Opt
iona
lTe
mp
Switc
h
AC
WIR
ING
Shield
217
202204
OVOV
24V
VFD WIRING DIAGRAM(FOR FLOOR MOUNTED GRUNDFOS PUMP)
HFI GRUNDFOS PUMP SECTION
S+S-
S+S+
S-S-
Jum
per
Jum
per
NCNCNC
OVOV
24V24V
OVOV
24V
204217
Jum
per
Ground
Jum
per
Curre
ntSw
itch
MAI
NSU1
W1
V1M
OTO
RU2
W2
V21
23
45
67
8
910
1112
1314
1516
Bloc
k 1Bl
ock 2
Powe
rFr
om F
uses
24 -
12 =
Cur
rent
Swi
tch
24 -
217
= Pr
essu
re T
rans
duce
r
24 -
204
= Te
mp
Switc
h or
Jum
per
Pum
p
Cap
Brow
n W
ire
Tran
sduc
er: B
rown
= 2
4VBl
ue =
217
Shiel
d =
Gree
n
Aqua
-Lab
Pane
l 1Aq
ua-L
abPa
nel 2
Opt
iona
lTe
mp
Switc
h
217
Shield
204202
54
32
1
DC
WIR
ING
© Hydra-Flex, Inc. 2017 Page | 16
GREY M12 CABLE DIAGRAM TWO PANELS(SINGLE FLOOR MOUNT GRUNDFOS PUMP & VFD)
Gra
y W
ire
Hom
e Ru
n Ca
ble
Gra
y W
ire
VFD
To Car Wash Controller
To Power 3PH
Pressure Sensor Wire
Note: Not all gray wireswill be used.
Water InletWater Outlet
Pressure Sensor
Grundfos Pump
LOCREM ?
STOPS START
HFI GRUNDFOS PUMP SECTION
© Hydra-Flex, Inc. 2017 Page | 17
1. Slideinhexnutsfromplumbingoutletmanifoldintoslotsonpumphousing
2. Fastenoutletmanifoldtopumphousing.Torqueboltsto~40footpounds.Ensuregasketislocatedcorrectly.
3. Verifythatthepumpvoltagematchesthesitevoltagethatwillbesuppliedtopowerthepump.Thereisavoltagelabelonthepumpcordindicatingwhichvoltagethepumpiswiredfor.Motorsareratedfor+10%oftheratedvoltageonthemotornameplate.
4. RoutepowerfromsitetoVFDbox.MakesurethatthesitepowerbeingsuppliedmatchestheVFDvoltage. Note: Do not run pump power cord within 6 ft of sensitive electronics. Route in independent conduit to prevent signal interference.
5. RoutepumppowercordtoVFD.
6. Routewatertopump.
a. Note: for 40 GPM pump, do not plumb any elbows or bends within 20 inches of the pump inlet. b.Note: for 20 GPM pumps, do not plumb any elbows or bends within 13 inches of pump inlet.
7. RoutepumpoutlettoAqua-LabHD/XDpanel.
8. Primethepumpbylooseningtheventpluglocatedatthetopofthepump.Airwillpurgethroughtheventhole.Pumpisprimedoncewaterbeginstoflowoutofthevent.Tightenventcapplug. a. Disconnect closed ball valve at Hydra-Cannon inlet and point towards drain or into bucket and slowly open ball valve to flush water and any air that might be trapped in line. Close and re-connect.
Fasten outlet manifold to pump housing
Slide Nuts Into Frame
CAUTION: DO NOT APPLY 480V TO A 230VAC VFD.
Main Site Supply PowerWhite to L1, Red to L2, Black to L3
Pump Power CordWhite to U2, Red to V2, Black to W2,
Ground to Grounding screw
Loosen Priming Vent To Purge Air
Pump Is Primed Once Water Begins To Come Out. Close Vent By Tightening Plug
9. Attachgraypressuretransducercabletopressuretransducer.
10. AttachremaininggraysignalcordstoAqua-LabHD/XDM12junctionblockspositionssixand8B. a. Note: The VFD control box has 3 M12 junction block signal cables attached. If the system does not require all three cords, leave cords coiled up and ensure cable ends are capped.
(Threads Into outlet of Pump)
START UP(SYSTEMS WITH VFD & GRUNDFOS PUMPS):
HFI GRUNDFOS PUMP SECTION
© Hydra-Flex, Inc. 2017 Page | 18
11. EnsureVFDisintheREMModebyusingthekeypadonthefrontfaceoftheVFD.
12. SEE PAGE 13 FOR INSTRUCTIONS ON WIRING YOUR VFD. YOUR VFD MUST BE WIRED IN ORDER FOR YOU TO VERIFY ROTATION. Verify Correct Rotation (in REM MODE):Pulsethepumponandoffbysendingasignalfromthecarwashcontrollerforachemicalfunctiontoturnon.Examinethefanbylookingdownwardontothepump.Verifythatthefanisspinninginthesamedirectionasindicatedonthemotorcasting.
a. Look downward onto motor to verify fan is rotating in the correct direction.
b. Turn signal off when complete. If pump is rotating backwards, switch any two lines that connect VFD power to the pump, ie: Switch U2 with V2 as shown in the image above in section 5. CAUTION: DO NOT WORK INSIDE VFD BOX UNTIL 10 MINUTES AFTER POWER DOWN.
13. SendsignalfromcarwashcontrollertoAqua-Labpaneltoturnonpump,verifythat180-200PSIwaterissuppliedtotheAqua-Labpanel.Usetheupanddownarrowsonthekeypadtoincrease/decreasepressure.
Press loc/REM Button Until REM Is Shown In The Top Left Of Screen
Direction On Motor Casting Indicating Correct Direction
FAULTSTheVFDhasthefollowingfaultprotectionstokeepthepumpandsystemsafe.Seetablebelow.
FAULT TYPE FAULT CAUSE SCREEN READ OUT
Low Inlet Pressure(FAULT 42)
1. No water supplied to pump inlet.2. Blown fuse on incoming power supply.3. Panel flow set up exceeds pump
performance curve (reduce injector sizes).4. Hose rupture.5. Pump running at low pressure for more
than 1 minute.
High Temperature(FAULT 14)
1. If temperature switch is wired in and the temperature exceeds switch set point, the temperature switch will fault out.
2. If the temperature switch is not installed make sure that there is a solid jumper between terminal block 24V and terminal block 204.
LOCREM ?
STOPS TART
LOC FAULT
INLET LOWRESET EXIT
FAULT 42
LOCREM ?
STOPS TART
REM FAULT
EXT FAULT 1RESET EXIT
FAULT 14
VFD MODESRemote Mode:ThistakesasignalfromacarwashcontrollertoturnonachemicalfunctionwhichtheninitiatestheVFDtostartthepump.TouseREMmode,presstheloc/rembuttonontheleftofthekeypaduntilREMappearsonthetopleftofthescreen.Sendasignalfromthecarwashcontrollertoactivatethepump.Usetheupanddownarrowsonthekeypadtoincrease/decreasepressure.
SAFETYCAUTION: WAIT 10 MINUTES AFTER POWERING DOWN THE VFD BEFORE
WORKING INSIDE THE BOX. THE VFD CONTAINS LARGE CAPACITORS AND 10 MINUTES IS NEEDED TO ALLOW THE CAPACITORS TO SAFELY DISCHARGE.
HFI GRUNDFOS PUMP SECTION
© Hydra-Flex, Inc. 2017 Page | 19
(Based on field experience this is HFI’s recommended starting point)1. Usingtherecommendedstartingpoint(Page28)orthetargetflowrateandthechemicaldilutions
chart(appendixPage27)installtheappropriateinjectorintoeachport.
2. Connectpre-runsolutionlinestoeachinjectorwiththesuppliedcouplerandpushconnectfitting.
a. Be sure to use Teflon tape when connecting the injector to the coupler and push connect fitting to ensure there are no leaks.
b. Do not over tighten poly fittings or they may crack.
3. Connect¼”polylinesfromeachchemicalcontainertothehosebarbontheappropriateinjector. a. Ensure a foot valve or similar check valve/filter is installed on each line.
i. These must be present or metering tips may clog.4. Meteringtipswillneedtobeinstalledtosetdilutionratio(seeappendixPage27forratiochartsto
determinetip.)
INITIAL INJECTOR SETUP
YourAqua-LabHD/XDpanelwasdesignwith Tri-Foamcapabilitythebelowinstructionswill showyouhowtosetupyourtriplefoam.
• Yourtriplefoamhasbeensetupfromthe factorytobeinthelastport(furthestright).
• Insertyourtriplefoammanifoldintothatpositionwithyourselectedinjectorsalreadyinserted.
• Onthetopsideofthepaneltheregulatorswillcontroltheairtoeachofyourtriplefoamcolors.
• Insertyourairlinestothearchintothe bulkheadfittingsonthesideofthepanel.Thebulkheadwillbetheairlinesforeachcolor.
Note: Occasionally if all three regulators are pre-set too high, you may need to lower all three regulators to their lowest setting and then turn them up to the desired pressure.
TRIPLE FOAM SETUP
APPENDIX
AB
C
AB
C
© Hydra-Flex, Inc. 2017 Page | 20
What do metering tips do?• Increasesordecreasestheamountof
chemicalinthesolution.
What do nozzles do?• Determinesthepatternandbackpressure
ofthesolution.
APPLICATION OPTIMIZATION(REPEAT FOR EACH APPLICATION)• Application too wet
• Increase foaming air pressure• Reduce injector size (decreases water)• Increase metering tip (increases
chemical)
• Application too dry• Decrease foaming air pressure• Increase injector size (increases water)• Decrease metering tip (decreases
chemical)
• Nozzle sputters• Decrease foaming air pressure• Decrease number of nozzle(s) and/or
size used on arch• Increase injector size (increases water)
• Too much chemical used• Decrease metering tip• Decrease metering tip and injector
size (to maintain desired ratio)
OPTIMIZING THE SYSTEMCONSISTENTLY ACHIEVE THE DESIRED CLEANING AND PRESENTATION/PERFORMANCE USING THE LEAST AMOUNT OF CHEMICAL AND WATERINJECTORS VS. METERING TIPS VS. NOZZLESTHE KEY TO OPTIMIZING THE SYSTEM IS THROUGH TRIAL AND ERROR. DON’T BE AFRAID TO TRY THESE STEPS TO ACHIEVE YOUR IDEAL PERFORMANCEWhat do injectors do?
• Increasesordecreasestheamountofwaterinthesolution.
• No chemical • Check vacuum/back-pressure of
injector for clogging (see page 26 for Injector Vacuum Check Instructions or page 23 for troubleshooting)
• Check foot valve• Check metering tip
• Nozzle fan pattern not filled• Reduce nozzle size• Increase injector size (increases water)
• Water not present at all nozzles on arch• Verify check valves are functioning• Verify nozzles are not plugged• Reduce number of nozzles• Reduce nozzle size• Increase injector size (increases water)
NOZZLE SETUP(Optional For Maximized Optimization)
• Usingtherecommendedstartingpoint(appendixpage28)installtherecommendednozzles.• Thismayinvolveremovingandpluggingsomeports.• DuetothelowerwaterusagedeterminedbytheinjectoroftheAqua-Labyouwillneedto
matchtheflowoftheapplicationdevicetotheinjector.• Setupthenozzlespraypatternsto“paint”thecar-slightlyoverlappingeachother.
© Hydra-Flex, Inc. 2017 Page | 21
MINIMUM NUMBER OF NOZZLES NECESSARY WITH FOAMING AIR(Assuming <10 PSI line loss and ~ 40 PSI at the nozzle)
SPRAY NOZZLE SIZE# 2.0 # 3.0 # 4.0 # 5.0 # 6.0 # 7.0 # 8.0 # 9.0 # 10.0
0.25 4 2 2 1 1 1 1 1 10.50 8 5 4 3 2 2 2 1 10.75 13 8 6 5 4 3 3 2 21.0 17 11 8 7 5 5 4 3 31.5 26 17 13 10 8 7 6 5 52.0 35 23 17 14 11 10 8 7 7
2.25 39 26 19 15 13 11 9 8 73.25 56 37 28 22 18 16 14 12 115.5 96 64 48 38 32 27 24 21 198.0 140 93 70 55 47 39 35 31 2810 175 116 87 69 58 49 44 38 3512 209 140 105 83 70 59 52 46 4115 262 175 131 104 87 74 65 57 52
INJE
CTO
R FL
OW
RAT
E @
200
PSI
(GPM
)
MINIMUM NUMBER OF NOZZLES NECESSARY WITHOUT FOAMING AIR(Assuming <10 PSI line loss and ~ 40 PSI at the nozzle)
SPRAY NOZZLE SIZE# 2.0 # 3.0 # 4.0 # 5.0 # 6.0 # 7.0 # 8.0 # 9.0 # 10.0
0.25 1 1 1 1 1 1 1 1 10.50 2 1 1 1 1 1 1 1 10.75 3 2 1 1 1 1 1 1 11.0 5 3 2 2 1 1 1 1 11.5 7 5 3 3 2 2 1 1 12.0 10 6 5 4 3 2 2 2 22.25 11 7 5 4 3 3 2 2 23.25 16 10 8 6 5 4 4 3 35.5 27 18 13 11 9 7 6 6 58.0 39 26 19 16 13 10 9 9 7
10.0 49 33 24 20 16 13 11 11 912.0 59 39 28 24 20 15 13 13 1115.0 74 49 35 30 25 19 16 16 14
INJE
CTO
R FL
OW
RAT
E @
200
PSI
(GPM
)
Elbows/Pipe Fittings• Elbowsandotherpipefittingsaddbackpressurebycausingthefluidtochangedirectionand
thuschangingthefluid’smomentum.Trytofindsimplerwaystorouteyourfluidwithoutelbows.
Line Length• Longerlinesaddbackpressureduetotheinherentresistancecausedbyfriction.Seeifyoucan
reducethelinelengthorincreasetheinsidediameter.
CHEMICAL USAGE MEASURINGVERIFY TITRATION OF CHEMICALS BEFORE PROCEEDING1. Setuplabscalewithsmallbucketofchemicaltobemeasured.
2. Putthesuctionlineintothebucket.
3. Runtheapplicationbeingtestedto“prime”theline.(Allairbubblesmustberemovedforaccuracy.)
4. RecordtheInitial Weight fromthescale.(Taringthescalewithweightonthescalecanaffectaccuracy.)5. Runtheapplicationfor1vehicle(ormanuallyforthesameamountoftimeitwouldbeonfor1
vehicle).
6. RecordtheFinal Weightfromthescale.7. SubtracttheInitialWeightfromtheFinalWeighttodeterminetheweightofusedproduct.
8. DividethePer Car Weightingramsbythespecificgravityofthechemicaltodeterminethemillilitersofchemicalusedpervehicle.
9. Repeatforeachchemicalapplication.
0
8
16
24
© Hydra-Flex, Inc. 2017 Page | 22
RECOMMENDED MAINTENANCETHE RECOMMENDED SERVICE AND MAINTENANCE ON THE AQUA-LAB SYSTEM ARE AS FOLLOWS. Monthly
• Check/drainprimaryairregulator/filterseparator.• Checkwaterfilterandreplaceasneeded(ifinstalled).• Checkandcleanwyestrainer.
Semi-Annually• Checkandreplaceinjectormeteringtips.• Inspectandreplacechemicallinesasneeded.• Ensurelinesaretightlysecuredtoinjectorhosebarbs,clip1”offoldhoseasneededthatwas
stretchedbyhosebarb.
Annually• Cleanwaterregulator.• Inspectmotorstarterforcorrosion,ifidentifiedorderreplacement/spareparts.
1-3 Years• Inspectandreplaceinjectors.• Replacewatervalves.• Replacemainpressureregulator.
AIR OPERATED VALVE REPLACEMENT1. ShutofftheballvalvetoHydra-Cannonmanifold.2. Disconnectairlinefromfrontofvalve.3. Unscrewquickconnectfittingbyhand(DO NOT LOSE BLACK WASHER).4. UnscrewvalveassemblyfromtheHydra-Cannonmanifold.5. Screwnewvalveintomanifolduntilhandtightandthreadedpilotportis
facingforward.6. Removethecapfrompilotportandthreadinquick
connectfittingtofrontofvalve–HAND TIGHT ONLY.7. Pushairlinebackintofitting.8. OpentheballvalvetotheHydra-Cannonmanifold.
BAM VALVE REPLACEMENT1. ShutoffthewatersupplyballvalvetotheBAMmanifold.2. Disconnectairlinefromfrontofmanifold.3. Removespringclipsfromassemblythatareadjacenttovalvebeingreplaced.4. Unboltvalveassemblyfromthepanel.5. Removevalvefromassembly.6. Installnewvalveintoassemblyensuringcorrectorientation.7. Reinstallspringclipsandboltvalveassemblytopanel.8. Pushairlinebackintofitting.9. OpenthewatersupplyballvalvetotheBAMmanifold.
Unscrew from manifold using this portion of valve
© Hydra-Flex, Inc. 2017 Page | 23
INJECTOR ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONSInjector Is Not Drawing Chemical - Passes Vacuum Pressure Check Cloggedchemicalfeed
Checkchemicalhose,footvalve,meteringtip,andhosebarbfordebrisorclogs.
No Flow From InjectorValvemalfunction,valvenotopening
Ensureminimum60psionprimaryairregulator,ensurevalvereceivingsignal.
Cloggedinjector Removeinjectorandblowoutdebriswithcompressedair.
Nowatersupply Checkthatthesystemhasasupplyofwater.
Injector Is Not Drawing Chemical - Fails Vacuum Pressure Check
ToomuchbackpressureoninjectorCleanorreplacedownstreamcheckvalves,increasenozzlesizeorquantity,uselargertubing,orusesmallerflowinjectors.
CloggedinjectorcheckvalveBlowcompressedairthroughthechemicalhosebarbontheinjectortoremovedebris.
Cloggedinjectornozzle Removeinjectorandblowoutanydebriswithcompressedair.
Defectiveinjector Replaceinjector.
Productspecific-Sonny’sRainBar Removeelbowatinlettofoamgeneratorandremovenozzle.
Manifoldinletclogged(rare)Removeendfittingsandretentionrod.Cleanoutinletholestoallowfullflow.
Injector stainless steel disintegrating Stronghydrofluoricacid CallHydra-Flexandordercompositeversionofinjectors.
PUMP ISSUESTROUBLESHOOTING
PROBLEM POTENTIAL CAUSES SOLUTIONS
Pump Operates, But Only Delivering 100-150 Psi Incorrectmotorrotation Reverserotationbyinterchangingtwoleads.
Pump Operates, But Delivers Little Or No Water
Pumpnotprimed Seepriminginstructions.
Missing1of3phases Wireaccordingtodiagram/checkbreaker(turnoffonback).
InadequatewatersupplyCheckpressureoninletsideofpumptobesurepositivepressureismaintained.
Undersizedpiping Replacewithlargerpiping.
Leakontheinletside Makesureconnectionsaretight.
Wornordefectivepumpparts Replacewornpartsorentirepump,cleanpartsifrequired.
Overheat Light OnInlettemptoohigh
Reduceinlettempto110°FMax,injectorflowto10GPMmax.
Injectorflowtoolow Increasecontinuousflowtoatleast3/4GPM.
Pump Will Not Start Or Run AtFull Speed
ConstanthotnotconnectedMakesureconstantcontrolvoltageissuppliedincarwashcontroller.
Blownfuseorcircuitbreaker
Couldbeduetoblownpumpmotor.Trytoturnbreakerbackonorreplacefuse.Ifbreakertripsaftertryingtofiremotoritismostlikelyburnedout.Replacewithnewmotorandpump.
Defectivemotorstartercontactor Replacemotorstartercontactor.
Thermaloverloadsettoolow/tripped Adjustsettingonthermaloverloadtomatchvoltage.
IncorrectmotorvoltageVoltagemustbewithin10%ofmotorratedvoltage.(Checkthatpumpiswiredforcorrectvoltage.)
Defectivemotor Replacemotor.
3phasedisconnectturnedoff Turndisconnecton.
Pumpcomponentsdamaged Replacewornpartorentirepump.
CurrentSensornotseeinganycurrent
Turnononevalveandverifyredlightblinksfast,verifyatleast10wrapsofwirearoundcurrentsensor.
© Hydra-Flex, Inc. 2017 Page | 24
FLOW / ARCH ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS
Flow At Arch Is Too Low
Incorrectinjectorflowrateselection
Replacewithlargerinjector
Systempressuretoolow Ensuresystempressureissetat200psi
Foamgeneratorplugged Ensurecleanedandclear
DownstreamplumbingrestrictiveIncreasesizeofplumbing/tubing,ensurecheckvalvesarecleanedornew,reduceelbowsinlineorotherturnsthatwouldrestrict
VALVE ISSUES
VFD ISSUES
PROBLEM POTENTIAL CAUSES SOLUTIONS
Valve Will Not Open
AirpressuretoolowEnsureprimaryairregulatorreadingatleast60psi,turnupto80-90psiifpossibleandcheckagain.
Internalvalveo-ringjammed/twisted
Removevalvefrommanifold,Carefullyremovetopofvalve (caution – under high spring pressure)pushwhitepistonupwithsmallallenwrenchfromoppositeendandchecko-ringcondition.Replaceandlubricateifneeded.
Valve Leaks Air Or Water Out Top
Internalo-ringsealdamaged/worn
Removevalvefrommanifold,Carefullyremovetopofvalve (caution – under high spring pressure)pushwhitepistonupwithsmallscrewdriverfromoppositeendandchecko-ringcondition.Replacewith018&008VitonO-ringandlubricatewithDow111valvelube.
Valve Remains Open After Signal Is Off
Manifoldpressureisabove230psi Reducepressuretomanifoldto200psioperatingpressure.
Airexhaustmufflerisclogged Replaceexhaustmuffler.
PROBLEM POTENTIAL CAUSES SOLUTIONS
Low Inlet Pressure (FAULT 42)Valve Leaks Air Or Water Out Top
Nowatersuppliedtopumpinlet. Verifywatersuppliedtopumpissufficient.
Blownfuseonincomingpowersupply.
Confirmcorrectelectricalsupplyandconnections.
Panelflowsetupexceedspumpperformancecurve.
Ensuretotalinjectorflowislessthanpumpsystemcanprovide.Reduceinjectorsize(s)ifneeded.
Waterpressureislessthan100psiforlongerthan1minute.
Checksystemforleaksorrupturedhoses.
High Temperature (FAULT 14)
Iftemperatureswitchiswiredinandthetemperatureexceeds180°F,thetemperatureswitchwillfaultout.
Ensureinletwatertemperatureislessthan140°F.
Ifatemperatureswitchisnotinstalled,falsesignaltoVFD.
Ensureasolidjumperbetweenterminalblock24Vandterminalblock204inthecontrolbox.
PRESSURE REGULATOR ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS
System Won’t Regulate Up To 200 Psi
Pumpnotprimed Followpriminginstructions.
Debrisinregulator Removeregulatorandcleanoutdebris.
Motorrotationincorrect Verifyrotation/switch2leads.
OpeningtoomanyvalvesatonceSystemislimitedbysizeofpumpandsizeofinjectors,increaseflowbyaddingsecondarypumpsorreducesize/numberofinjectorsopen.
Defectivecheckvalve(ifapplicable) Replacecheckvalve.
DefectiveRegulator Replaceregulator.
DefectivePump ReplacePump.
PressureTransducerissetincorrectlyorisbroken
RefertoPumpManualtoverifytransducersettingorreplacetransducer.
PressureTransducercableislooseordamaged
Ensuregoodconnectionsorreplacecable.
© Hydra-Flex, Inc. 2017 Page | 25
STEPS:1. Plugtheoptimizationtoolintothe
outletlineofinjectorandconnectsolutionoutputline.
2. TurnonfunctionfromcarwashcontrollertoactuateHydra-Cannonvalvesuchthatfluidisflowingthroughboththeinjectorandinjectoroptimizationtoolandouttotheapplicator.
3. Readinjectoroptimizationtool.
4. Ifthegaugeisinthe“RED ZONE”thebackpressureoftheoutletlineiseithertoolowortoohigh.Seestepsbelowtocorrect. Solution
Output Line
Hydra-Cannon Valve
Injector Optimization Tool
Injector
Chemical Draw Line
Chemical Bucket
BACKGROUND:ThistoolisforinitialsetupandtroubleshootingofChem-Flex™InjectorsandanAqua-LabHD/XDChemicalDispensingSystem.Inorderfortheinjectortoworkproperlyanddrawchemicalthisgaugemustbeinthe“GREEN”sectionwheninstalledimmediatelyafteraninjectorthatisrunning.Ifthegaugeisintheredyouwilleithersee:intermittentchemical,nochemicaldraw,orchemicalbeingappliedataverylowpressure.
Backpressurereferstothepressureinthesolutionoutputline.Excessivebackpressureisthemainreasonthatinjectorswillnotdraw.Ifthereiseveranyconcerntowhyaninjectorisnotdrawingchemical,thebestandeasiestwaytodiagnosetheproblemistocheckthebackpressure.Seeinstructionsbelow:
INJECTOR OPTIMIZATION TOOL
BACK PRESSURE TOO HIGH (UPPER RED SECTION):(Back Pressure May Be Affected By One Or Several Of These Things)
1. Foamgeneratorsareclogged/degraded.Cleanorreplacemediaingenerator.2. Injectorflowsizeistoolarge.Godownaninjectorsize(lessGPM).3. Nozzlesizeonthearchistoosmall.Goupinnozzlesize.4. Checkvalvesaredirtyandorfailing.Cleanorreplacecheckvalves.5. Thereisakinkinthelineorexcessfittings(elbowsandreducersincreasethebackpressure).
Checklineandreplaceanykinkedsections.Trytoreducefittings.6. IDoftubinggoingouttothetunnelistoosmall.Goupasizeininsidediameter.7. Checkvalveshavetoohighofcrackingpressure.Replacecheckvalvewithlowerpressurecheckvalve.8. Cleanfootvalve.
BACK PRESSURE TOO LOW (LOWER RED SECTION):(Back Pressure May Be Affected By One Or Several Of These Things)
1. Injectorflowtoolow.Increaseinjectorsize.2. Nozzlesizetoolarge.Reducenozzlesize.
© Hydra-Flex, Inc. 2017 Page | 26
INJECTOR VACUUM CHECK
C
B
(FOR TROUBLESHOOTING INJECTORS) 1. AttheChem-Flexinjector,removethechemicalfeedlinefrom
theinjectorhosebarb.
2. AttachthetubingofthevacuumgaugetotheChem-Flexhosebarb(ImageA).
3. Withthepump(s)on,manuallyactivatethechemicalthatistobetestedatthemaincarwashcontrolcabinet.Aninjectorthatisworkingproperlywillhaveareadinggreaterthanorequalto(≥) 20inHg.
4. Ifvacuumreads<20in/Hg(imageB),removesolutionmetering tip(imageC)andretest. a. If retest vacuum reads >20 in/Hg (image D), The solution metering tip is clogged. Replace the metering tip. b. If Retest vacuum reads <20 in/Hg, continue to STEP 5
5. Removeanozzleonthearchorthechemicalfeedlinefromthefoamgeneratorandretestvacuum. a. If retest vacuum reads >20 in/Hg, back pressure is being created. Continue to STEP 6. b. If back pressure is not still not being created try these steps and retest after each:
1. Clean nozzle tips. 2. Loosely replace media in foam generator. Do not over pack. 3. Decrease air pressure for foaming. 4. Try smaller injector (this will produce less flow and thus less back pressure).
c. If retest vacuum reads <20 in/Hg, replace injector and retest. If vacuum continues to read <20 in/ Hg, call your service provider.
6. Repeatsteps2-5foreachchemicallanethatavacuumreadingisneededfor.
7. Oncetestingiscomplete,turnofftheAqua-LabHD/XDpumpfromthemaincarwashcontrolcabinet.
A
D
HFI MCU HIGH TEMP SHUTDOWN RESTART INSTRUCTIONS1. Closeballvalveonpanelandquickdisconnecthigh
pressurewaterline.
*** Purge pressure before disconnecting (pressure gauge to read 0 PSI before disconnecting).2. Pointhosetodrainandopenballvalvetopurgehotwater
andcoolpumpforseveralminutes(USECAUTION).
3. Whenpumpissufficientlycooledcloseballvalve,reconnecthose,openballvalveandpressredbuttononMCUtorestart.
4. Determinewhysystemoverheated.Seemanualfortroubleshooting(page22Overheat Light On)
1.
2.
3.
© Hydra-Flex, Inc. 2017 Page | 27
CHEM-FLEX INJECTORS - CHEMICAL DILUTION RATIOS
3.00
”1:
251
1: 5
031:
754
1: 1
006
1: 1
509
1: 2
012
1: 2
263
1: 2
416
1: 2
460
1: 2
628
1: 4
526
1: 5
532
1: 8
047
1: 1
0059
1: 1
2070
1: 1
5088
2.00
”1:
181
1: 3
631:
544
1: 7
261:
108
91:
145
11:
163
31:
140
21:
133
71:
151
01:
326
61:
399
11:
580
61:
725
71:
870
81:
108
85
1.00
”1:
104
1: 2
081:
311
1: 4
151:
623
1: 8
311:
934
1: 8
351:
778
1: 8
981:
186
91:
228
41:
332
21:
415
31:
498
31:
622
9
0.75
”1:
82
1: 1
651:
247
1: 3
291:
494
1: 6
591:
741
1: 6
421:
668
1: 7
551:
148
31:
181
21:
263
61:
329
51:
395
41:
494
2
0.50
”1:
59
1: 1
191:
178
1: 2
381:
357
1: 4
751:
535
1: 4
871:
496
1: 5
581:
106
91:
130
71:
190
11:
237
61:
285
21:
356
4
0.25
”1:
34
1: 6
81:
102
1: 1
361:
204
1: 2
721:
306
1: 2
821:
304
1: 3
441:
612
1: 7
481:
108
81:
136
01:
163
21:
204
0
Spiral Plug Length
#8
-32
MET
ERIN
G T
IPS
Flow
Rat
e(G
PM) a
t 200
PSI
0.25
0.50
0.75
1.00
1.50
2.00
2.25
3.00
3.25
3.75
4.50
5.50
8.0
10.0
12.0
15.0
Inje
ctor
Col
orW
hite
Yello
wTa
nRe
dO
rang
eG
ray
Blue
Ligh
t Bl
ueLi
ght
Gre
enPi
nkPu
rple
Dar
k G
reen
Blac
kBl
ack
Blac
kBl
ack
Noz
zle
Size
0.02
9”
(0.7
mm
)0.
040”
(1.0
mm
)0.
051”
(1.3
mm
)0.
057”
(1.4
mm
)0.
070”
(1.8
mm
)0.
083”
(2.1
mm
)0.
086”
(2.2
mm
)0.
095”
(2.4
mm
)0.
098”
(2.5
mm
)0.
106”
(2.7
mm
)0.
117”
(2.9
mm
)0.
125”
(3.2
mm
)0.
161”
(4.1
mm
)0.
117”
(4.5
mm
)0.
186”
(4.7
mm
)0.
207”
(5.3
mm
)
CO
PPER
1: 5
71:
104
1: 1
551:
195
1: 2
811:
406
1: 4
681:
598
1: 6
291:
739
1: 8
811:
107
41:
201
91:
231
81:
332
41:
425
9
PUM
PKIN
1: 4
31:
82
1: 1
191:
126
1: 2
381:
348
1: 3
981:
519
1: 5
541:
647
1: 7
741:
946
1: 1
465
1: 1
832
1: 2
310
1: 3
042
BURG
UN
DY
1: 3
41:
67
1: 9
71:
111
1: 2
071:
304
1: 3
471:
461
1: 4
951:
575
1: 6
901:
845
1: 1
244
1: 1
670
1: 1
975
1: 2
469
LIM
E1:
28
1: 5
71:
81
1: 1
001:
183
1: 2
701:
307
1: 4
141:
447
1: 5
181:
622
1: 7
641:
988
1: 1
262
1: 1
481
1: 1
958
TAN
1: 2
81:
57
1: 8
11:
100
1: 1
831:
270
1: 3
071:
414
1: 4
471:
518
1: 6
221:
764
1: 8
261:
104
21:
128
61:
155
7
ORA
NG
E1:
23
1: 4
41:
64
1: 7
81:
137
1: 1
961:
215
1: 2
931:
314
1: 3
651:
437
1: 5
361:
751
1: 8
741:
113
61:
126
2
TURQ
UO
ISE
1: 1
71:
31
1: 4
51:
55
1: 9
11:
126
1: 1
341:
185
1: 1
971:
230
1: 2
741:
336
1: 5
611:
752
1: 8
851:
109
9
PIN
K1:
14
1: 2
41:
35
1: 4
21:
68
1: 9
31:
98
1: 1
301:
143
1: 1
591:
188
1: 2
241:
372
1: 4
731:
570
1: 7
28
LIG
HT
BLU
E1:
11
1: 1
71:
24
1: 3
11:
47
1: 6
41:
66
1: 9
31:
98
1: 1
141:
136
1: 1
661:
318
1: 4
061:
483
1: 5
72
BRO
WN
1: 1
01:
15
1: 2
21:
28
1: 4
31:
58
1: 5
91:
84
1: 8
81:
103
1: 1
221:
150
1: 2
701:
338
1: 4
081:
507
RED
1: 1
21:
17
1: 2
31:
34
1: 4
51:
46
1: 6
51:
69
1: 8
01:
95
1: 1
161:
202
1: 2
541:
306
1: 3
75
WH
ITE
1: 1
21:
16
1: 2
21:
31
1: 4
21:
43
1: 6
11:
64
1: 7
41:
88
1: 1
081:
180
1: 2
261:
272
1: 3
43
GRE
EN1:
11
1: 1
41:
20
1: 2
81:
37
1: 3
81:
53
1: 5
51:
65
1: 7
61:
94
1: 1
601:
201
1: 2
411:
300
BLU
E1:
10
1: 1
21:
17
1: 2
31:
30
1: 3
11:
44
1: 4
61:
53
1: 6
31:
77
1: 1
221:
152
1: 1
851:
224
YELL
OW
1: 9
1: 1
21:
16
1: 2
01:
22
1: 3
01:
31
1: 3
61:
42
1: 5
21:
80
1: 1
001:
120
1: 1
48
BLA
CK
1: 1
01:
13
1: 1
61:
17
1: 2
31:
24
1: 2
81:
33
1: 4
01:
61
1: 7
71:
92
1: 1
15
PURP
LE1:
6.6
1: 8
.31:
91:
10
1: 1
31:
13
1: 1
51:
17
1: 2
11:
31
1: 3
91:
46
1: 5
7
GRA
Y1:
5.3
1: 6
.71:
6.9
1: 7
.61:
9.9
1: 1
01:
11.
61:
13
1: 1
61:
24
1: 3
01:
35
1: 4
4
OPE
N1:
4.9
1: 5
.31:
5.2
1: 6
.01:
6.1
1: 6
.11:
7.6
1: 8
.31:
10
1: 1
21:
15
1: 1
81:
23
Metering TipNO
TE: D
iluti
on
rati
os
giv
en a
re b
ased
on
dra
win
g w
ater
thr
oug
h th
e m
eter
ing
tip
s an
d a
re m
eant
as
a st
arti
ng p
oin
t fo
r sy
stem
co
nfig
urat
ion.
R
esul
ts a
re e
xpec
ted
to
var
y w
hen
dra
win
g c
hem
ical
s d
ue t
o d
iffer
ence
s in
vis
cosi
ty a
nd t
emp
erat
ure.
The
re m
ay b
e sl
ight
var
iati
ons
of
per
form
ance
in
inje
cto
rs a
nd m
eter
ing
tip
s th
at a
re u
navo
idab
le d
ue t
o m
anuf
actu
re t
ole
ranc
es. U
sing
the
sam
e ti
p c
olo
r fr
om
sit
e to
sit
e is
a g
oo
d s
tart
ing
po
int.
H
ow
ever
, wit
h th
e p
ote
ntia
l fo
r va
riat
ion
fro
m p
art,
to
par
t it
is r
easo
nab
le t
o s
till
need
to
do
so
me
adju
stm
ents
fro
m t
here
.
3/7”
po
lyflo
w (L
LDP
E) t
ubin
g is
req
uire
d t
o e
nsur
e a
seal
bet
wee
n th
e tu
be
wal
l and
the
sp
iral
plu
g.
(Ass
umes
feed
pre
ssur
e of
200
PSI
(14
bar)
)
© Hydra-Flex, Inc. 2017 Page | 28
RECOMMENDED SETUP STARTING POINTS
FoamingAir:Startat25PSI(adjustbasedonuniqueapplication)
PC2 INJECTOR PART NUMBERS
Foroptimalperformance,matchtheflowoftheinjectortotheflowofthenozzlesorapplicator.Thismayinvolvechangingnozzlesand/orremovingorpluggingsomeports.Seebelowforrecommendedsetupstartingpoints.
APPLICATOR INJECTOR(S) PART NUMBER/COLORScentDispenser (1.0 GPM) (3.8 LPM)
CTANozzles(ForShowerhead,SeeBelow) (1.0 GPM) (3.8 LPM)
FoamStick (1.5 GPM) (5.7 LPM)
Mitter/WrapNozzles (1.5 GPM) (5.7 LPM)
Undercarriage/RustInhibitor (2.0 GPM) (7.6 LPM)
VJetOrFlatFanNozzleArch (2.25 GPM) (8.5 LPM)
K12NozzleArch (2.25 GPM) (8.5 LPM)
K15NozzleArch (3.25 GPM) (12.3 LPM)
HockeyPuck1 Row Of Holes
(0.75 GPM) (2.8 LPM)2 Rows Of Holes
(1.0 GPM) (3.8 LPM)3 Rows Of Holes
(1.5 GPM) (5.7 LPM)
Showerhead1 Row Of Holes
(1.0 GPM) (3.8 LPM)2 Rows Of Holes
(1.5 GPM) (5.7 LPM)3 Rows Of Holes
(2.0 GPM) (7.6 LPM)
Rain Bar1 Row Of Holes
(2.25 GPM) (8.5 LPM)2 Rows Of Holes
(3.25 GPM) (12.3 LPM)3 Rows Of Holes
(5.5 GPM) (20.8 LPM)
LowFlowFoamCurtain-ChooseFoamAccessoryBasedOn#OfInputs/FoamGenerators
Duo-Foam With (2X)(3.25 GPM) (12.3 LPM)
Triple-Foam With (3X)(2.25 GPM) (8.5 LPM)
HighFlowFoamCurtainApplication-WorksWithUpTo4Inputs/FoamGenerators
(8.0 GPM) (8.5 LPM) With Distribution Manifold
(XD, HD)
(10.0 GPM) (37.9 LPM) With Distribution Manifold
(XD, HD)
(12.0 GPM) (45.2 LPM) With Distribution Manifold
(XD, HD)
INLET CONNECTION PC2* (QUICK-CONNECT)
OUTLET CONNECTION 3/8” MNPT
FOR USE WITH AQUA-LAB MODEL(S) MD, XD, HD
COLOR FLOW ORIFICE FLOW RATE @ 200 PSI (14 bar) SINGLE BARB DUAL BARB
White 0.029” (0.74 mm) 0.25 GPM (1.0 LPM) 618029 -
Yellow 0.040” (1.02 mm) 0.50 GPM (1.9 LPM) 618040 629040
Tan 0.051” (1.39 mm) 0.75 GPM (2.8 LPM) 618051 629051
Red 0.057” (1.45 mm) 1.00 GPM (3.8 LPM) 618057 629057
Orange 0.070” (1.78 mm) 1.50 GPM (5.7 LPM) 618070 629070
Gray 0.083” (2.11 mm) 2.00 GPM (7.6 LPM) 618083 629083
Dark Blue 0.086” (2.18 mm) 2.25 GPM (8.5 LPM) 618086 629086
Light Blue 0.095” (2.41 mm) 3.00 GPM (11.3 LPM) 618095 629095
Light Green 0.098” (2.49 mm) 3.25 GPM (12.3 LPM) 618098 629098
Pink 0.106” (2.69 mm) 3.75 GPM (14.2 LPM) 618106 629106
Purple 0.117” (2.98 mm) 4.50 GPM (17.0 LPM) 618117 629117
Dark Green 0.125” (3.18 mm) 5.50 GPM (20.8 LPM) 618125 629125
© Hydra-Flex, Inc. 2017 Page | 29
Max Pressure Inlet / Outlet Up to 250 PSI (17 bar)
Temperature Range 33°F - 140°F (.5°C - 60°C)
Maximum Wrench Torque (PC2) Hand Tighten Only (30 in-lbs)
Maximum Wrench Torque (PC3) Hand Tighten Only (60 in-lbs)
INLET CONNECTION PC3*
OUTLET CONNECTION 3/4” MNPT
FOR USE WITH AQUA-LAB MODEL(S) XD, HD
COLOR FLOW ORIFICE FLOW RATE @ 200 PSI (14 bar) SINGLE BARB
Black 0.161” (4.09 mm) 8.00 GPM (30.3 LPM) 818161
Black 0.177” (4.50 mm) 10.0 GPM (37.9 LPM) 818177
Black 0.186” (4.72 mm) 12.0 GPM (45.2 LPM) 818186
Black 0.207” (5.30 mm) 15.0 GPM (56.8 LPM) 818207
SPECIFICATIONS
*For exclusive use with Aqua-Lab Chemical Dispensing Systems.
PC3 CHEM-FLEX INJECTOR PART NUMBERS
*For exclusive use with Aqua-Lab Chemical Dispensing Systems.
Max Pressure InletNPT up to 1000 PSI (69 bar)
PC2 up to 500 PSI (34 bar)
Max Pressure Outlet 333 PSI (23 bar)
Temperature Range 33°F - 175°F (.5°C - 79°C)
Maximum Wrench Torque 30 ft-lbs (41 N-m)
SPECIFICATIONS
PRESSURE LOSS IN RUN LENGTH
All solution line tubing should be selected for 10 PSI or less of pressure loss.*20 PSI pressure loss may be acceptable depending upon nozzle sizing, foamers, check valves and other line restrictions present in application.All numbers represent pressure loss in PSI for selected solution line tubing.
GREEN = GOOD YELLOW= USE CAUTION RED = NOT RECOMMENDED
5/8” ID BRAIDEDINJECTOR
Flow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.00 3.25 3.75 4.50 5.50
Injector Color White Yellow Tan Red Orange Gray DarkBlue
LightBlue
Light Green Pink Purple Dark
Green
Nozzle Size 0.029”(0.7 mm)
0.040”(1.0 mm)
0.051”(1.3 mm)
0.057”(1.4 mm)
0.070”(1.8 mm)
0.083”(2.1 mm)
0.086”(2.2 mm)
0.095” (2.41 mm)
0.098”(2.5 mm)
0.106” (2.69 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 6 PSI 7 PSI 9 PSI 13 PSI* 18 PSI*125’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 8 PSI 11 PSI* 16 PSI*100’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 9 PSI 13 PSI*75’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 3 PSI 4 PSI 5 PSI 7 PSI 9 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 3 PSI 5 PSI 6 PSI25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI
Run
Leng
th
© Hydra-Flex, Inc. 2017 Page | 30
INJECTORFlow Rate (GPM) at 200 PSI 8.0 10.0 12.0 15.0
Injector Color Black Black Black Black
Nozzle Size 0.161”(4.09 mm)
0.177”(4.50 mm)
0.186”(4.72 mm)
0.207”(5.26 mm)
100’ 10 PSI 15 PSI* 21 PSI 32 PSI75’ 8 PSI 11 PSI* 16 PSI* 24 PSI50’ 5 PSI 8 PSI 11 PSI* 16 PSI*25’ 3 PSI 4 PSI 6 PSI 8 PSIRu
n Le
ngth
3/4” ID BRAIDED
INJECTORFlow Rate (GPM) at 200 PSI 8.0 10.0 12.0 15.0
Injector Color Black Black Black Black
Nozzle Size 0.161”(4.09 mm)
0.177”(4.50 mm)
0.186”(4.72 mm)
0.207”(5.26 mm)
100’ 3 PSI 4 PSI 5 PSI 8 PSI75’ 2 PSI 3 PSI 4 PSI 6 PSI50’ 1 PSI 1 PSI 3 PSI 4 PSI25’ 1 PSI 1 PSI 2 PSI 2 PSIRu
n Le
ngth
1” ID BRAIDED
1/2” ID BRAIDED
3/8” ID, 1/2” OD POLY TUBE
INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.00 3.25 3.75 4.50 5.50
Injector Color White Yellow Tan Red Orange Gray Blue LightBlue
LightGreen Pink Purple Dark
Green
Nozzle Size 0.029”(0.7 mm)
0.040”(1.0 mm)
0.051”(1.3 mm)
0.057”(1.4 mm)
0.070”(1.8 mm)
0.083”(2.1 mm)
0.086”(2.2 mm)
0.095” (2.41 mm)
0.098”(2.5 mm)
0.106” (2.69 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 9 PSI 11 PSI* 18 PSI* 21 PSI 27 PSI 36 PSI 56 PSI125’ 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 8 PSI 9 PSI 15 PSI* 18 PSI* 23 PSI 30 PSI 47 PSI100’ 1 PSI 1 PSI 2 PSI 2 PSI 4 PSI 7 PSI 8 PSI 12 PSI* 14 PSI* 18 PSI* 24 PSI 36 PSI75’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 6 PSI 9 PSI 11 PSI* 14 PSI* 18 PSI* 26 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 4 PSI 4 PSI 6 PSI 8 PSI 9 PSI 12 PSI* 18 PSI*25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 9 PSI
Run
Leng
th
INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.00 3.25 3.75 4.50 5.50
Injector Color White Yellow Tan Red Orange Gray Blue LightBlue
LightGreen Pink Purple Dark
Green
Nozzle Size 0.029”(0.7 mm)
0.040”(1.0 mm)
0.051”(1.3 mm)
0.057”(1.4 mm)
0.070”(1.8 mm)
0.083”(2.1 mm)
0.086”(2.2 mm)
0.095” (2.41 mm)
0.098”(2.5 mm)
0.106” (2.69 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 1 PSI 5 PSI 7 PSI 11 PSI* 22 PSI 36 PSI 44 PSI 76 PSI 88 PSI 115 PSI 154 PSI 239 PSI125’ 1 PSI 4 PSI 6 PSI 9 PSI 18 PSI* 30 PSI 37 PSI 63 PSI 73 PSI 101 PSI 129 PSI 200 PSI100’ 1 PSI 3 PSI 5 PSI 7 PSI 14 PSI* 23 PSI 28 PSI 50 PSI 54 PSI 77 PSI 103 PSI 142 PSI75’ 1 PSI 2 PSI 4 PSI 6 PSI 12 PSI* 18 PSI* 22 PSI 37 PSI 42 PSI 53 PSI 77 PSI 106 PSI50’ 1 PSI 1 PSI 3 PSI 4 PSI 8 PSI 12 PSI* 15 PSI* 25 PSI 28 PSI 39 PSI 52 PSI 73 PSI25’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 7 PSI 12 PSI* 13 PSI* 19 PSI* 26 PSI 34 PSI
Run
Leng
th
© Hydra-Flex, Inc. 2017 Page | 31
PART NAME PART NUMBERDuo-Foam Kit (HD/XD) 1002267
Triple-Foam Kit (HD/XD) 1002268
Distribution Manifold (HD/XD) 1002289
High-Flow Rinse Kit (PC2) 1001230
Anti-Siphon Kit (PC3) 1002230
PC3 To PC2 Adapter (HD/XD) 1002094
Injector Optimization Tool 1002018
Vacuum Tester Kit 1001104
Water Filtration System - Cold 1001431
Water Filtration System - Cold Replacement Filter 3000855
PC2 Plug - Stainless Steel 3000022
Flow-Through Adapter 3000173
Bug Prep Foam Generator For Prep Gun Replacement 1001750
Bug Prep Foaming Prep Gun Replacement 1001751
Bug Prep Foaming Prep Gun,Hose, & Injector Replacement 1001754
Bug Prep Dual Lumen 3/8” Spiral Hoe 30’ (9 m) 1002254
Aqua-Lab Rack Mounting Kit (Motor Control Unit Mounted Rack) 1002090
Aqua-Lab Rack Mounting Kit (Variable Frequency Drive Mounted Rack) 1002146
Aqua-Lab Rack Mounting Kit (Rack Tray Option) 1002080
Stainless Steel Motor Drip Shield (Wall Mounted Booster Pumps Only) 3001347
Kick Plate Cover (Floor Mounted Grundfos Pump Only) 1002159
Vinyl Hose Barb Cap 3000745
Remote Metering Device/Check Hub 1001756
3/8” Coupler 3000522
3/8” Elbow 3000523
3/8” x 1/2” Push-To-Connect 3000526
3/8” Check Valve (PC2) 3000970
3/4” Check Valve (PC3) 3002091
3/4” to 3/4”” Hose Barb & Check Valve Kit (PC3) 1002384
3/4” to 1” Hose Barb & Check Valve Kit (PC3) 1002386
AQUA-LAB HD/XD - ACCESSORIES
© Hydra-Flex, Inc. 2017 Page | 32
113
2
3
17
5
14
15
27/28
25
26
46
1216
2310
789
11
13
2
184
15
627/28
12
23or24
10
78
9
11
AQUA-LAB PANEL PARTS DIAGRAM
2526
© Hydra-Flex, Inc. 2017 Page | 33
NUMBER PART NAME PART NUMBER1 Air Actuated Hydra-Cannon Valve Replacement Kit - Stainless 3000925
2 Single BAM Valve Replacement 1002216
3 10-32” x 1/4” Push-To-Connect Air Fitting For Air Actuated Valve 3000987
4 BAM Valve Repair Kit 1002223
5 Hydra-Cannon Valve O-Ring Repair Kit 1001155
6 BAM O-Ring Repair Kit 1002222
7 Solenoid Actuated Air Valve - Foaming
24VAC - 1001428
24VDC - 1001429
120VAC - 1001430
8 Solenoid Coil Replacement For Air Actuated Valve
24 VAC - 3001149
24 VDC - 3001150
120 VAC - 3001151
9 M12 X Din I Cordset24 VAC/VDC - 3001957
120 VAC - 3001958
10 Primary Air Regulator 1001184
11 Primary Air Regulator Replacement Bowl 3002410
12 Foaming Small Air Regulator & 60 PSI Gauge 3001762
13 Outlet Pressure Gauge 0-400 PSI Bottom Mount 3000491
14 Inter Face Fitting Assembly 3001815
15 BAM Inlet Kit 1002396
16 Hydra-Cannon To BAM Coupler 3001956
17 Hydra-Cannon End Plug Assembly 3000561
18 BAM End Cap Kit 1002395
19 (Not Shown) 1/4” Push To Connect Tee 3000815
20 (Not Shown) 1/4” Push To Connect To 1/8” NPT Elbow 3000803
21 (Not Shown) 1/4” Push To Connect To 1/8” NPT Elbow - Plastic 3002033
22 (Not Shown) 1/4” Hose Barb Foaming Air Check Valve 3000819
23 M12 Junction Block - 8 Port, With Homerun Cable30’ (10 m) - 3001366-03
100’ (30 m) - 3001366-100
24 M12 Junction Block - 6 Port, With Homerun Cable30’ (10 m) - 3001301
100’ (30 m) - 3001302
25 Ball Valve 1” - 3000509
26 Manifold Inlet 1” ID Hose X 1” NPT Ends - 72” (1.8 m) Long 3001732
27 Male Quick Connect - Brass 1” - 3000205
28 Female Quick Connect - Brass 1” - 3000206
© Hydra-Flex, Inc. 2017 Page | 34
33 38
37
36
31
41
28
39
27282930 or 31
34
35
32
NUMBER PART NAME PART NUMBER27 Male Quick Connect - Brass 1” - 3000205
28 Female Quick Connect - Brass 1” - 3000206
29 1” Wye Strainer - 30 Mesh 3000490
30 1” NPT T16 Wye Strainer Screen & Gasket Kit 1001938
31 1” NPT T15 Wye Strainer Screen & Gasket Kit 1001939
32 40 GPM (150 LPM) Bypass Pressure Regulator - Stainless Steel 3000464
33 Quick Connect 9’ (3 m) Cordset For Booster Pump 3000782
34 Temperature Switch Assembly 3000507
35 20 GPM (75 LPM) Quick Connect Regulator Plumbing Assembly 1002340
36 40 GPM (150 LPM) Grundfos Plumbing Assembly 1002130
37 Grundfos Pump System Manifold O-Ring 3001878
38 Replacement/Backup 40 GPM (150 LPM) Grundfos Pump 3001618
39 Replacement/Backup 20 GPM (75 LPM) Booster Pump 1001362
40 (Not Shown) Booster Pump Floor Stand 1002250
41 Dual Booster Pump Wall Mount Bracket 3000921
42 (Not Shown) Triple Booster Pump Wall Mount Bracket 3000950
AQUA-LAB PUMP PARTS DIAGRAM
© Hydra-Flex, Inc. 2017 Page | 35
48 or 4944 47 45 46 55
59
48or49
58
53
50or51
54
NUMBER PART NAME PART NUMBER43 (Not Shown) M12 Cordset (Gray) 3000347
44 High-Temp Light 3002512
45 Quick Connect Pump Plug - Female 3000783
46 Thermal Overload - Eaton 1002757
47 Timer Relay 1002758
48 Current Sensor - AC 3000666
49 Current Sensor - DC 3000866
50 VFD Replacement - 5HP230V - 1002664
480V - 1002666
51 VFD Replacement - 7.5HP230V - 1002665
480V - 1002667
52 (Not Shown) VFD MCU Keypad 3002373
53 VFD MCU Exhaust Fan 3001869
54 VFD MCU Exhaust Filter 3001868
55 Contactor - Eaton
24 VAC - 3001336
24 VDC - 3001337
120 VAC - 3001338
56 (Not Shown) VFD MCU Pressure Transducer 3001705
57 (Not Shown) Pressure Transducer Cable 3001867
58 VFD MCU Primary Fuse 1/2 AMP 3001870
59 VFD MCU Fuse30A - 3001871
60A - 3001872
AQUA-LAB CONTROL PARTS DIAGRAM
© Hydra-Flex, Inc. 2017 Page | 36
T:952-808-3640•www.hydraflexinc.com•[email protected]
4000087 revF0917
FACTORY LIMITEDHydra-Flex,Incwarrantsitsequipmenttobefreefromdefectinmaterialorworkmanshipunderproper
normaluseforaperiodofone(1)yearbeginningthedateofpurchase.
Hydra-Flex,Inc’sliabilityshallbelimitedtorepairorreplacementofpartsfoundtobedefectivewithinthe
warrantyperiodandfollowingHydra-Flex,Inc’sinspection.Hydra-Flex,Incshallhavetheoptionrequiring
thereturnofdefectivematerialtoestablishthepurchaser’sclaim.Intheeventofrepairorreplacement
thislimitedwarrantyisnon-cumulative.Neitherlabornortransportationchargesareincludedinthis
warranty.
Thiswarrantyisbaseduponthepropercareandmaintenanceofthewarrantedequipment.Warranty
doesnotapplyifthemerchandiseisalteredormodifiedinanyway.Warrantydoesnotapplytoany
equipmentwhichhasbeensubjecttomisuse,inappropriateuseoftools,includingexposuretoharsh
chemicals,neglect,lackofmaintenance,freezing,fluidhammer,accident,thirdpartydamage,fluid
impuritiessuchassandorminerals,actsofGodoractsofwar.Nordoesitapplytoanyequipmentwhich
hasbeenrepairedoralteredbyanyonenotsoauthorizedbyHydra-Flex,Inc.Allequipmentmustbe
properlyinstalledinaccordancewithspecifiedplumbing,electrical,andmechanicalrequirements.The
warrantydoesnotapplytonormalwearandtearorroutinemaintenancecomponentsasdescribedinthe
equipmentmanual.
Exceptasexpresslystatedherein,Hydra-Flex,Incshallnotbeliablefordamagesofanykindin
connectionwiththepurchase,maintenance,oruseofthisequipmentincludinglossofprofitsandall
claimsforconsequentialdamages.Thislimitedwarrantyisinlieuofallotherwarrantiesexpressedor
implied.Hydra-Flex,Incneitherassumesnorauthorizesanypersontoassumeforitanyotherobligation
orliabilityinconnectionherewith.Thiswarrantyisneitherassignablenortransferable.
Transportationdamageclaimsaretobesubmittedtothecarrierofthedamagedmaterial.
AQUA-LAB HD/XD™ WARRANTY