zvc assure pds with aqua-lab™ technology...assure pds system diagram mounting slots (2 top, 2...

© Hydra-Flex, Inc. 2018© Hydra-Flex, Inc. 2018

ZVC ASSURE PDS WITHAQUA-LAB™

TECHNOLOGYCHEMICAL DISPENSING SYSTEM

User ManualREV F

4000029 revF0118

© Hydra-Flex, Inc. 2018

Specifications 1

AssurePDSSystemDiagram 2

MotorStarter/PumpDiagram 3

LayoutDrawing 4

EstimatedInstallationTimeline 5

InstallationInstructions 6

WiringDiagram 8SinglePump 8Multi-Source/DualPump 10

StartUp 12

InitialInjectorSetup 13

TripleFoamSetup 13

OptimizingTheSystem 14

NozzleSetup 14

ChemicalUsageMeasurement 15

RecommendedMaintenance 16

AirOperatedValveReplacement 16

TroubleShooting 16PumpIssues 16InjectorIssues 17PressureRegulatorIssues 17Flow/Archissues 18ValveIssues 18

InjectorOptimizationTroubleshooting 18

InjectorVacuumCheck 19

Appendix 20Chem-FlexInjectorDilutionRatioChart 20RecommendedSetupStartingPoint 21Chem-FlexInjectorPartNumbers 21PressureLossInRunLength 22ReplacementPartsList 23Aqua-LabWarranty 24

TABLE OF CONTENTS

SPECIFICATIONSAIR-ACTUATED VALVES

24 VAC or 24 VDC or 120 VAC, 3.5 Watts Per Port

PUMPS

20 GPM

208-230V/3PH/8.9A or 460V/3PH/4.2A

POWER REQUIREMENTS

DIMENSIONS (W x H)

WATER SUPPLY

AIR SUPPLY

MOTOR CONTROL UNIT

Single / Dual

14” x 15”

PANELS

MD3 MD5

22” x 29” 22” x 29”

FULL STAND

Width 47.5” x Height 78” x Depth 28”

PUMP ASSEMBLIES

1-Pump 2-Pump 3-Pump

24”x 48” 24” x 48” 36” x 48”

Air Inlet Line 3/8” OD Polyflow Per MD Panel

Air Outlet Line 3/8” OD Polyflow Per Application

Air Inlet Pressure 20 CFM @ 80-120 PSI Dry Air

Water Inlet Lines20 GPM 40 GPM

1” ID 1 1⁄2” ID or 2x 1” ID

Solution Outlet LinesUp to 2.25 GPM 3.25 - 4.5 GPM 5.5 GPM

3/8” ID (1⁄2” OD Polyflow*) 1⁄2” ID* 5⁄8” ID*

Operating Water Pressure 200 PSI (Factory Set) Assuming 40 PSI City Feed

Maximum Water Source Temperature Recommended 110°F (43°C) - (max water temp) 137°F (58°C) with Booster Pump

Water Filtration (Suggested) 50 Micron

FOR ADDITIONAL SUPPORT CALL: 952-808-3640OR VISIT US ON THE WEB: www.hydraflexinc.com

Page | 1

*Assuming line length is 50’ (15 m) or less. Refer to user page 20 for recommended size chart for other lengths.

© Hydra-Flex, Inc. 2018 Page | 2

ASSURE PDS SYSTEM DIAGRAM

Mounting Slots (2 top, 2 Bottom)

Individual Air Regulators

Tri-Foam Manifold

Solution Ports (Front)Air Ports (Back)

Hydra-Cannon Manifold

M12 Junction Block

Solenoid Actuated Air Valves

Primary Air Regulator

16 3/8”

REFER TO PAGE 23 FOR PART NUMBERS & DIAGRAMS

Home RunCable (Goes to car wash controller for control voltage)

1

2

3

4

5A

5A

5B

5B

5C

5C

1

1 2 3 4 5A 5C

2 3 4 5

Grey M12 Cable (Goes To Motor Starter Box)


MOTOR STARTER/PUMP DIAGRAM(SINGLE SOURCE / SINGLE PUMP SHOWN)

REFER TO PAGE 24 FOR PART NUMBERS & DIAGRAMS

Wye-Strainer Pump Outlet Feed Line To MD Panels

Bypass Pressure Regulator

Timer Relay

Contactor

Thermal Overload

Temperature Shutdown Relay

Current Switch3 Phase Disconnect

Quick Connect Pump Plug Female

Back-up Pump

Temperature SwitchQuick Connect 9’ Cordset For Pump (Plugs Into Bottom Of Motor Starter)

Grey M12 Cables (Carry signal from yellow M12 distribution block to motor starter that turns on the pump)

EATON


LAYOUT DRAWING

Page | 4

21.9”

47.5”

15.75”

5 Port Assure PDS

(1x) Connection With Valve To Accommodate 1" Male Npt Hose MustTerminate Within 5 Feet Of Pump Inlet (Ø1.0" Recommended) Provided By Others

(2x) 20' Signal WireTo AQUA-LAB Included

(1x) 230V / 480V PumpPower Receptacle Included

(1x) 12ft 230V / 480VPump Power Cord Included With Each Pump

(1x) 6' X Ø1.0" MNPT Quick Change Pump Inlet Hose Included

(2x) 3/8" Poly Flow Air Inlet TubingProvided By Others (100 PSI Max)

(1x) 6' Quick Change Flexible Hose With Regulator & WyeStrainer To Assure PDS With 1/2" Quick Connect & Ball Valve Included With Each

13”

78”

30' SignalControl Cable

Included


5 EASY STEPS FOR INSTALLATIONCOMPLETE PRE-INSTALLATION CHECKLIST BEFORE THESE STEPS

1. Unpack

2. Setskidinplace

3. Makeconnections

4. Start-up

5. Optimizingtheequipment

5 EASY STEPS FOR INSTALLATION

WHO TASK EST. TIME

ZVC REP MONITOR & RECORD PERFORMANCE 2HR/WK

ZVC REP MAINTENANCEPERSCHEDULEORASNEEDED

POST INSTALLATION

TOTAL HOURS SPENT

INSTALLATION

TOTAL CUSTOMER .5 HR

TOTAL ZVC REP 13.75 HR

TOTAL ELECTRICIAN 4 HR

TOTAL PLUMBER 4 HR

PRE-INSTALLATION

ESTIMATED TIMELINE

WHO TASK EST. TIME

ZVCREP&CUSTOMER DETERMINELOCATIONTOINSTALLEQUIPMENT .25HR

PLUMBER/ZVCREP INSTALLWATERSUPPLYLINE 1 HR

ELECTRICIAN INSTALLELECTRICALSUPPLYLINE 2 HR

TECHNICIAN/ZVCREP LABELALLCONTROLLERRELAYSATCONTROLLER .5HR

TECHNICIAN/ZVCREP RUNSOLUTIONANDAIRLINES(IFNECESSARY) 5HR

TECHNICIAN/ZVCREP INSTALLAIRSUPPLYLINE 1 HR

TOTAL LABOR HOURS 9.75 HRS

WHO TASK EST. TIME

ZVCREP/TECHNICIAN SETSKIDINPLACEANDBOLTTOWALL .5HR

ZVCREP/TECHNICIAN CONNECTWATER,AIRANDSOLUTIONLINES 1 HR

TECHNICIAN CONNECTCONTROLLEADSTOMAINCONTROLLERORJUNCTIONBOX 2 HR

ZVCREP/TECHNICIAN STARTUP(INJECTOR,METERINGTIPANDNOZZLESELECTION) 2 HR

ZVCREP/TECHNICIAN DOCUMENTCONFIGURATION .5HR

TOTAL LABOR HOURS 6 HRS

InstallationtakesapproximatelyONEday.Anelectricianandaplumberareneededforhalfaday.


General Skill Level• Mechanical:Basic-mountingequipment

• Electrical:Advanced-threephasepowerandcontrolsknowledge(localcodesknowledgerequired)

• Plumbing:Moderate-principalsupplylinerequired

• Pneumatic:Basic-pneumaticutilityconnectionrequired

• ChemicalKnowledge:Moderate-chemicaltitrationsrequired

UNPACKINGTheAQUA-LABPDSisshippedonapallet.

1. Cutstrapsholdingskidtopallet

2. Un-bolttheskidfromthepallet.

3. Lifttheskidfromthepallet.Useassistanceifnecessary.

4. ***Be sure not to discard the manuals and accessories box.

LOCATION & MOUNTING**IflocationwasnotidentifiedduringthePre-InstallationProcess,makesuretoconsidertheproximitytofeedwater,powersupply,andthecontrolcabinetaswellasspacenearthesystemtostorechemicalcontainers.

***See drawing in reference for general layout1. Setskidinlocationidentified

2. Optional:Boltskidtowallusingwallanchorplates

INSTALLATION INSTRUCTIONS

• Utilityknife

• Wirestripper

• Adjustablewrench

• Screwdriverset

• Socketset

• Teflontape

Tools & Equipment Needed• DrillwithPhillipshead

• Concretedrillbit5/32”

Useful Tools:• AmpMeter

• VoltMeter

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


******************(HFI supplied motor starter)******************

1. ELECTRICAL CONNECTIONS (HFI MOTOR STARTER)a. Wire yellow homerun control cables to car wash control panel. (See diagram below for wiring schematic)

• Manifold position below designates which 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.

b. Remove the cap from port 6 then, connect the gray M12 cables hanging out of the motor starter box to the NEUTRAL/COMMON port 6 of the yellow M12 junction boxes.

i. If you have more panels than gray wires from the motor starter box, 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 motor(s) to motor starter box.d. Connect male plug to outlet previously installed by electrician.

• Make sure to follow all applicable electrical codes.

1

12

3

4

5

3

12

3

4

5

5

12

3

4

5

2

12

3

4

5

4

12

3

4

5

6

12

3

4

5

Ground - Green/yellow

Do Not Use - Blue (Cap With Wire Nut)

Neutral / Common - Red

Hydra-Cannon Port 1 - White

Hydra-Cannon Port 2 - Green

To Motor Starter Box

Hydra-Cannon Port 3 - Yellow

Hydra-Cannon Port 4 - Grey

Hydra-Cannon Port 5 - Pink

Control Voltage Constant Hot / + Brown

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!).

(Left to right on water manifold, top to bottom on air valves refer to diagram on page 2)

PNEUMATIC CONNECTIONS• Connectpre-run3/8”ODpolyfeedlinetopushconnectfitting

onthesideoftheprimaryregulator.

• Connect3/8”ODpolylinesfromarchtoeachport thatwillbefoaming.

**If there are unused air ports, back out the individual line regulator until air no longer flows.


15

A1B1

1618 A2

TIMER

RELAY

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

ACCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FROM

BREAKER

CONTRO

L VOLTAGE

24/120VAC SINGLE SOURCE SINGLE PUM

P3 PHASE

24/120VAC SINGLE SOURCE SINGLE PUM

P

4000149_RevC0118

34

RELAY 1

34

15

A1B1

1618 A2

TIMER

RELAY

112223

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

ACCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1P1

RELAY 1

TS2TS1

112223

TS2TS1


15

A1B1

1618 A2

TIMER

RELAY

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

DCCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FROM

BREAKER

CONTRO

L VOLTAGE

24VDC SINGLE SOURCE SINGLE PUM

P3 PHASE

24VDC SINGLE SOURCE SINGLE PUM

P

34

RELAY 1

34

15

A1B1

1618 A2

TIMER

RELAY

112223

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1P1

RELAY 1

TS2TS1

112223

TS2TS1

DCCURRENTSENSO

R

34

21

5

4000147_RevC0118

Page | 9


34

34

34

34

15

A1B1

1618 A2

TIMER

RELAY

15

A1B1

1618 A2

TIMER

RELAY

TS3TS4

112223

3A

TS2TS1

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

RELAY 2

845113

14129

ACCURRENTSENSO

R

ACCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1P1

P2

15

A1B1

1618 A2

TIMER

RELAY

15

A1B1

1618 A2

TIMER

RELAY

TS3TS4

112223

3A

TS2TS1

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

RELAY 2

845113

14129

ACCURRENTSENSO

R

ACCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FROM

BREAKER

RELAY 2

RELAY 2

RELAY 1

RELAY 1

CONTRO

L VOLTAGE

24/120VAC DUAL SOURCE DUAL PUM

P3 PHASE

24/120VAC DUAL SOURCE DUAL PUM

P

4000150_RevC0118


ACCURRENTSENSO

R

ACCURRENTSENSO

R

34

21

53

42

15

34

34

15

A1B1

1618 A2

TIMER

RELAY

15

A1B1

1618 A2

TIMER

RELAY

TS3TS4

112223

3A

TS2TS1

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

RELAY 2

845113

14129

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1P1

P2

15

A1B1

1618 A2

TIMER

RELAY

15

A1B1

1618 A2

TIMER

RELAY

TS3TS4

112223

3A

TS2TS1

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

RELAY 2

845113

14129

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FROM

BREAKER

CONTRO

L VOLTAGE

RELAY 2

34

RELAY 2

34

RELAY 1

RELAY 1

DCCURRENTSENSO

R

DCCURRENTSENSO

R

34

21

53

42

15

3 PHASE24VDC DUAL SO

URCE DUAL PUMP

24VDC DUAL SOURCE DUAL PUM

P4000148_RevC0118

Page | 11


START UPPUMP MUST BE PRIMED BEFORE OPERATION!WARNING!

1. FLUSHMakesurewatersupplytopumpisturnedon.Openballvalveanddirecttowardadrainorcontainertoremovethemajorityoftheairfromthepumpuntilasteadystreamofwaterisflowing(approx. 1 min).Thenclosetheballvalve.

2. CHECK ROTATIONOpenAqua-Lab™MotorControlUnit(MCU)andensure3phasedisconnectison.(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!Startthepumpmomentarilybydepressingthecenterofthecontractor(image 2).!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 ConnectthepumpoutletlinetotheHydra-CannonManifoldandopenballvalve.

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.

Image 1

Image 2

Image 5

Image 6Image 7


(Based on field experience this is HFI’s recommended starting point)1. Usingtherecommendedstartingpoint(Page21)orthetargetflowrateandthechemicaldilutions

chart(appendixPage20)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(seeappendixPage20forratiochartsto determinetip.)

INITIAL INJECTOR SETUP

(For ASSURE PDS if ordered with extra regulators)If your MD5 panel was ordered with 3 air valves and 5 air regulators or with 5 air valves and 7 air regulators the below instructions will show you how to setup your triple foam.

3 Valve / 5 Regulator ASSURE PDS• Yourtriplefoamhasbeensetupfromthefactorytobeinport 3.

• Insertyourtriplefoammanifoldintoposition3withyourselectedinjectorsalreadyinserted.

• Onthesideofthepanelthe3rd(3A),4th(3B),and5th(3C)regulators(numberingstartsatthetop)willcontroltheairtoeachofyourtriplefoamcolors.

• Insertyourairlinestothearchintothebulkheadfittingsonthebottomofthepanel.The3rd(3A),4th(3B),and5th(3C)bulkhead(countingfromlefttoright)willbetheairlinesforeachcolor.

5 Valve / 7 Regulator ASSURE PDS• Yourtriplefoamhasbeensetupfromthefactorytobeinport 5.

• Insertyourtriplefoammanifoldintoposition5withyourselectedinjectorsalreadyinserted.

• Onthesideofthepanelthe5th(5A),6th(5B),and7th(5C)regulators(numberingstartsatthetop)willcontroltheairtoeachofyourtriplefoamcolors.

• Insertyourairlinestothearchintothebulkheadfittingsonthebottomofthepanel.The5th(5A),6th(5B),and7th(5C)bulkheadfittings(countingfromlefttoright)willbetheairlinesforeachcolor.

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


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/backpressure of

injector for clogging (see page 19 for Injector Vacuum Check Instructions or pages 17 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)

(Optional For Maximized Optimization)• Usingtherecommendedstartingpoint(appendix)installtherecommendednozzles.

• Thismayinvolveremovingandpluggingsomeports.• DuetothelowerwaterusagedeterminedbytheinjectoroftheASSUREPDSyouwillneedto

matchtheflowoftheapplicationdevicetotheinjector.• Setupthenozzlespraypatternsto“paint”thecar-slightlyoverlappingeachother.

NOZZLE SETUP


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 19IN

JECT

OR

FLO

W R

ATE

@ 2

00 P

SI (G

PM)

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 2

2.25 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 5IN

JECT

OR

FLO

W R

ATE

@ 2

00 P

SI (G

PM)

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.(Tarringthescalewithweightonthescalecanaffectaccuracy.)5. Runtheapplicationfor1vehicle(ormanuallyforthesameamountoftimeitwouldbeonfor1

vehicle).

6. RecordtheFinal Weightfromthescale.7. SubtracttheInitialWeightfromtheFinalWeighttodeterminetheweightofusedproduct.

8. DividethePer Car Weightingramsbythespecificgravityofthechemicaltodeterminethemillilitersofchemicalusedpervehicle.

9. Repeatforeachchemicalapplication.

0

8

16

24


RECOMMENDED MAINTENANCETHE RECOMMENDED SERVICE AND MAINTENANCE ON THE ASSURE PDS 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. ShutofftheballvalvetoASSUREPDSorHydra-Cannonmanifold.2. Disconnectairlinefromfrontofvalve.3. Unscrewquickconnectfittingbyhand(DO NOT LOSE BLACK WASHER).4. UnscrewvalveassemblyfromtheHydra-Cannonmanifold.5. Screwnewvalveintomanifolduntilhandtightandthreadedpilotportisfacing

forward.6. Removethecapfrompilotportandthreadinquick

connectfittingtofrontofvalve–HAND TIGHT ONLY.7. Pushairlinebackintofitting.8. OpentheballvalvetotheHydra-Cannonmanifold.

Unscrew from manifold using this portion of valve

PUMP ISSUES

TROUBLESHOOTING

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.


Excessive Noise From Pump

Pumpnotsecuredfirmly Secureproperly.

Restrictedinlet Cleanorcorrectrestriction.

Waterregulatorfluttering/chattering

Trytoadjustregulatordownandthenbackuporreplaceregulator/removecheckvalves/pressureregulatorsfromH20feedtopump.

Cavitation(soundslikemarblesinpump) Increaseinletsize/inletpressure.

Wornmechanicalseal Replacepump.

Notprimed Re-primepump.

Pump LeaksLoosefittings,andornotenoughthreadtape

Tightenfittings,andortakepartoffandputnewthreadtapeon.

Failedseals Replacepump.

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.

PROBLEM POTENTIAL CAUSES SOLUTIONS

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.

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 StrongHydro-FluoricAcid CallHydra-Flexandordercompositeversionofinjectors.

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.


FLOW / ARCH ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS

Flow At Arch Is Too Low

Incorrectinjectorflowrateselection

Replacewithlargerinjector

Systempressuretoolow Ensuresystempressureissetat200psi

Foamgeneratorplugged Ensurecleanedandclear

DownstreamplumbingrestrictiveIncreasesizeofplumbing/tubing,ensurecheckvalvesarecleanedornew,reduceelbowsinlineorotherturnsthatwouldrestrict

VALVE ISSUESPROBLEM 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.

BACKGROUND:ThistoolisforinitialsetupandtroubleshootingofChem-Flex™InjectorsandanASSUREPDSChemicalDispensingSystem.Inorderfortheinjectortoworkproperlyanddrawchemicalthisgaugemustbeinthe“GREEN”sectionwheninstalledimmediatelyafteraninjectorthatisrunning.Ifthegaugeisintheredyouwilleithersee:intermittentchemical,nochemicaldraw,orchemicalbeingappliedataverylowpressure.

Backpressurereferstothepressureinthesolutionoutputline.Excessivebackpressureisthemainreasonthatinjectorswillnotdraw.Ifthereiseveranyconcerntowhyaninjectorisnotdrawingchemical,thebestandeasiestwaytodiagnosetheproblemistocheckthebackpressure.Seeinstructionsbelow:

INJECTOR OPTIMIZATION TOOL

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


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.

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,turnofftheASSUREPDSpumpfromthemaincarwashcontrolcabinet.

A

D

Page | 19


APPENDIXCHEM-FLEX INJECTORS - CHEMICAL DILUTION RATIOS

(Assumes feed pressure of 200 PSI)

NOTE: Dilution ratios given above are based on drawing water through the metering tips and are meant as a starting point for system configuration. Results are expected to vary when drawing chemicals due to differences in viscosity and temperature.

***Remove all standard metering tips when using a Metering Plug in an application. 3/8” Polyflow (LLDPE) tubing is required to ensure a seal between the tube wall and the flats on the OD of the Meter Plug.

There may be slight variations of performance in injectors and metering tips that are unavoidable due to manufacture tolerances. Using the same tip color from site to site is a good starting point. However with the potential for variation from part to part it is reasonable to still need to do some adjustments from there.

#8-32 METERING TIPS

Flow Rate(GPM) at 200 PSI

0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.25 4.50 5.50

Injector Color White Yellow Tan Red Orange Gray Blue Light Green 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)

0.098”(2.5 mm)

0.117”(2.9 mm)

0.125”(3.2 mm)

COPPER 1: 57 1: 104 1: 155 1: 195 1: 281 1: 406 1: 468 1: 629 1: 881 1: 1074

PUMPKIN 1: 43 1: 82 1: 119 1: 126 1: 238 1: 348 1: 398 1: 554 1: 774 1: 946

BURGUNDY 1: 34 1: 67 1: 97 1: 111 1: 207 1: 304 1: 347 1: 495 1: 690 1: 845

LIME 1: 28 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 447 1: 622 1: 764

TAN 1: 28 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 447 1: 622 1: 764

ORANGE 1: 23 1: 44 1: 64 1: 78 1: 137 1: 196 1: 215 1: 314 1: 437 1: 536

TURQUOISE 1: 17 1: 31 1: 45 1: 55 1: 91 1: 126 1: 134 1: 197 1: 274 1: 336

PINK 1: 14 1: 24 1: 35 1: 42 1: 68 1: 93 1: 98 1: 143 1: 188 1: 224

LIGHT BLUE 1: 11 1: 17 1: 24 1: 31 1: 47 1: 64 1: 66 1: 98 1: 136 1: 166

BROWN 1: 10 1: 15 1: 22 1: 28 1: 43 1: 58 1: 59 1: 88 1: 122 1: 150

RED 1: 12 1: 17 1: 23 1: 34 1: 45 1: 46 1: 69 1: 95 1: 116

WHITE 1: 12 1: 16 1: 22 1: 31 1: 42 1: 43 1: 64 1: 88 1: 108

GREEN 1: 11 1: 14 1: 20 1: 28 1: 37 1: 38 1: 55 1: 76 1: 94

BLUE 1: 10 1: 12 1: 17 1: 23 1: 30 1: 31 1: 46 1: 63 1: 77

YELLOW 1: 9 1: 12 1: 16 1: 20 1: 22 1: 31 1: 42 1: 52

BLACK 1: 10 1: 13 1: 16 1: 17 1: 24 1: 33 1: 40

PURPLE 1: 6.6 1: 8.3 1: 9 1: 10 1: 13 1: 17 1: 21

GRAY 1: 5.3 1: 6.7 1: 6.9 1: 7.6 1: 10 1: 13 1: 16

OPEN 1: 4.9 1: 5.3 1: 5.2 1: 6.0 1: 6.1 1: 8.3 1: 10

Met

erin

g Ti

p

SPIRAL METERING PLUGS

Flow Rate(GPM) at 200 PSI

0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.25 4.50 5.50

Injector Color White Yellow Tan Red Orange Gray Blue LightGreen 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)

0.098”(2.5 mm)

0.117”(2.9 mm)

0.125”(3.2 mm)

3.00” 1: 251 1: 503 1: 754 1: 1006 1: 1509 1: 2012 1: 2263 1: 3269 1: 4526 1: 5532

2.00” 1: 181 1: 363 1: 544 1: 726 1: 1089 1: 1451 1: 1633 1: 2359 1: 3266 1: 3991

1.00“ 1: 104 1: 208 1: 311 1: 415 1: 623 1: 831 1: 934 1: 1350 1: 1869 1: 2284

0.75” 1: 82 1: 165 1: 247 1: 329 1: 494 1: 659 1: 741 1: 1071 1: 1483 1: 1812

0.50” 1: 59 1: 119 1: 178 1: 238 1: 357 1: 475 1: 535 1: 772 1: 1069 1: 1307

0.25” 1: 34 1: 68 1: 102 1: 136 1: 204 1: 272 1: 306 1: 442 1: 612 1: 748

Spira

l Plu

g Le

ngth


RECOMMENDED SETUP STARTING POINTSAPPLICATOR INJECTORS PART NUMBER/COLORScentDispenser 618057 (1 GPM)

CTANozzles(ForShowerhead,SeeBelow) 618057 (1 GPM)

FoamStick 618070 (1.5 GPM)

Mitter/WarpNozzles 618070 (1.5 GPM)

Undercarriage/RustInhibitor 618083 (2.0 GPM)

VJetOrFlatFanNozzleArch 618086 (2.25 GPM)

K12NozzleArch 618086 (2.25 GPM)

K15NozzleArch 618098 (3.25 GPM)

HockeyPuck 1 Row Of Holes618051 (.75 GPM)

2 Rows Of Holes618057 (1 GPM)

3 Rows Of Holes618070 (1.5 GPM)

Showerhead 1 Row Of Holes618057 (1 GPM)



RainBar 1 Row Of Holes618086 (2.25 GPM)



FoamCurtain-ChooseFoamAccessoryBasedOn#OfInputs/FoamGenerators**

Duo-Foam w/(2X) 618098 (3.25 GPM)

Triple-Foam w/(3X) 618086 (2.25 GPM)

Quad-Foam w/(4X) 618086 (2.25 GPM)

HighFlowFoamCurtainApplication(10+GPM) High Flow Device w/ 618086 (2.25 GPM)

FoamingAir:Startat25PSI(adjustbasedonuniqueapplication)

CHEM-FLEX INJECTOR PART NUMBERS

Pressure Range: Up to 500 PSI Max. (34 bar) Inlet, 333 PSI (23 bar) Max. Outlet

Temperature Range: 33°F - 175°F ( .5°C - 79°C)

Maximum Wrench Torque: 30 ft-lbs (41 N-m)

SPECIFICATIONS

QUICK CONNECT INJECTORS - PC2 X 3/8” NPT CONNECTIONS(For exclusive use with Aqua-Lab™ Chemical Dispensing Systems)

COLOR FLOWORIFICE

FLOW RATE @ 200 PSI

SINGLE BARB DUAL BARB

WHITE 0.029 0.25 GPM 618029 -

YELLOW 0.040 0.5 GPM 618040 629040

TAN 0.051 0.75 GPM 618051 629051

RED 0.057 1.0 GPM 618057 629057

ORANGE 0.070 1.5 GPM 618070 629070

GRAY 0.083 2.0 GPM 618083 629083

BLUE 0.086 2.25 GPM 618086 629086

LIGHT GREEN 0.098 3.25 GPM 618098 629098

PURPLE 0.117 4.5 GPM 618117 629117

DARK GREEN 0.125 5.5 GPM 618125 629125


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

INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.25 4.50 5.50

Injector Color White Yellow Tan Red Orange Gray Blue Light Green 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)

0.098”(2.5 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 7 PSI 13 PSI* 18 PSI*125’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 6 PSI 11 PSI* 16 PSI*100’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 5 PSI 9 PSI 13 PSI*75’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 7 PSI 9 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 6 PSI25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI

Run

Leng

th

5/8” ID BRAIDED




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)

0.098”(2.5 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* 21 PSI 36 PSI 56 PSI125’ 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 8 PSI 9 PSI 18 PSI* 30 PSI 47 PSI100’ 1 PSI 1 PSI 2 PSI 2 PSI 4 PSI 7 PSI 8 PSI 14 PSI* 24 PSI 36 PSI75’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 6 PSI 11 PSI* 18 PSI* 26 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 4 PSI 4 PSI 8 PSI 12 PSI* 18 PSI*25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 4 PSI 6 PSI 9 PSI

Run

Leng

th

1/2” ID BRAIDED




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)

0.098”(2.5 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 88 PSI 154 PSI 239 PSI125’ 1 PSI 4 PSI 6 PSI 9 PSI 18 PSI* 30 PSI 37 PSI 73 PSI 129 PSI 200 PSI100’ 1 PSI 3 PSI 5 PSI 7 PSI 14 PSI* 23 PSI 28 PSI 54 PSI 103 PSI 142 PSI75’ 1 PSI 2 PSI 4 PSI 6 PSI 12 PSI* 18 PSI* 22 PSI 42 PSI 77 PSI 106 PSI50’ 1 PSI 1 PSI 3 PSI 4 PSI 8 PSI 12 PSI* 15 PSI* 28 PSI 52 PSI 73 PSI25’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 7 PSI 13 PSI* 26 PSI 34 PSI

Run

Leng

th

3/8” ID, 1/2” OD POLY TUBE


REPLACEMENT PARTS LIST - ASSURE PDS

A

B

Q

D

E

F

G N I

J

K

L

H

M

O

P

C

PART NAME PART NUMBERA MDPrimaryAirRegulator 1001184

BSolenoidActuatedAirValveReplacement-Foaming

24 VAC - 1001428

24 VDC - 1001429

120VAC-1001430

C M12XDinIAirRegulator-WithLED120VAC-3000948

24VDCor24VAC-3000958

D PrimaryAirRegulatorReplacementBowlAluminum-3000952

Plastic-3000870

E M12JunctionBlock-6Port,With30’HomerunCable 3001301

F OutletPressureGauge0-400PSIBottomMount 3000491

G AirActuatedHydra-CannonValveReplacementKit StainlessSteel-3000925

H 1/4”PolyTubing 3000812

IDuo-FoamManifoldKit(NOTSHOWN) 1001289

Tri-FoamManifoldKit 1001288

J SmallRegulator&0-60PSIGauge 3000808

K 10-32”X1/4”Push-To-ConnectAirFittingForAirValve 3000987

L 1/4”PushToConnectTee 3000815

M 1/2”NPTMaleQuickConnect-Brass 3000500

N SingleBlackHydra-CannonReplacementAssembly 1001384

O Hydra-CannonEndFittingAssembly 1001556

P Hydra-CannonInterfaceFittingAssembly 1002034

Q 3/8”PolyTubing 3000520

(NOTSHOWN) SolenoidO-RingReplacementKit 1001155

(NOTSHOWN) 1/4”HoseBarbFoamingAirCheckValve 3000819

(NOTSHOWN) 1/4”PushToConnectTo1/8”NPTElbow 3000803

(NOTSHOWN) Anti-SiphonKit(Contains5) 1001436

Page | 23


ASSURE PDS SINGLE SOURCE MOTOR STARTER

ASSURE PDS PUMP

J

I

H

KA

D

F E

BC G

PART NAME PART NUMBERA Replacement/Backup20GPMPump 1001362

B 1”MaleQuickConnect-Brass 3000205

C 1”WyeStrainer,20Mesh 3000490

D 1”FemaleQuickConnect-Brass 3000206

E TemperatureSwitch 3000507

F QuickConnect9’CordsetForPump 3000782

G 40GPMBypassPressureRegulator-StainlessSteel 3000464

(NOTSHOWN) 1”NPTT16WyeStrainerScreen&GasketKit 1001938

(NOTSHOWN) 1”NPTT15WyeStrainerScreen&GasketKit 1001939

(NOTSHOWN) 20GPMQuickConnectRegulatorPlumbingAssembly 1001775

(NOTSHOWN) 1/2”FemaleQuickConnect-Brass 3000502

(NOTSHOWN) 1/2”BallValve-Brass 3000565

(NOTSHOWN) ManifoldInletHose1/2”IDHose-1/2”NPTEnds-72”L 3000579

(NOTSHOWN) 20GPMQuickConnectRegulatorPlumingAssembly 1001775

PART NAME PART NUMBERH ThermalOverload-Sprecher&Schuh 3000862

I

Contactor-Sprecher&Schuh

24VAC-3000863

24VDC-3000864

120VAC-3000865

Contactor-Eaton

24VAC-3001336

24VDC-3001337

120VAC-3001338

J CurrentSensorAC-3000666

DC-3000866

K TimeRelay 3000664

REPLACEMENT PARTS LIST

Page | 24


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.

ASSURE PDS WARRANTY

T:952-808-3640•F:952-808-3650•www.hydraflexinc.com•[email protected]

4000022 revF0118

zvc assure pds with aqua-lab™ technology...assure pds system diagram mounting slots (2 top, 2...

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