AQUA-LAB HD/XD CHEMICAL DISPENSING SYSTEM. User Manual REV L revl1018

Transcription

1 AQUA-LAB HD/XD CHEMICAL DISPENSING SYSTEM User Manual REV L revl08 Hydra-Flex, Hydra-Flex, Inc. 08 Inc. 08 Page

2 TABLE OF CONTENTS Specifications Layout Drawing Panel Diagram Estimated Installation Timeline Installation Instructions Electrical Connections 7 HFI Booster Pump & MCU 8 Component Diagram 9 Wiring Diagram 0 Start Up Instructions 8 HFI Grundfos Pump & Variable Frequency Drive (VFD) 0 Component Diagram 0 Wiring Diagram Start Up Instructions Appendix Initial Injector Setup Triple Foam Setup Optimizing The System Nozzle Setup Chemical Usage Measuring 7 Recommended Maintenance 8 Air Operated Valve Replacement 8 BAM Valve Replacement 8 Troubleshooting 9 Pump Issues 9 Injector Issues 9 Pressure Regulator Issues 0 Flow / Arch issues 0 Valve Issues 0 VFD Issues 0 Injector Optimization Tool Injector Vacuum Check High Temp Shutdown Restart Instructions Chem-Flex Injectors - Chemical Dilution Ratios Recommended Setup Starting Points Chem-Flex Injector Part Numbers Pressure Loss In Run Length Aqua-Lab Accessories 7 Aqua-Lab Panel Parts Diagram 8 Aqua-Lab Pump Parts Diagram 0 Aqua-Lab Control Parts Diagram Aqua-Lab Warranty FOR ADDITIONAL SUPPORT CALL OR VISIT US ON THE WEB Hydra-Flex, Inc. 08 Page

3 0 GPM (7 LPM) HP Booster Pump SPECIFICATIONS POWER REQUIREMENTS 0 GPM (7 LPM) HP Grundfos Pump 0 GPM (0 LPM) 7. HP Grundfos Pump Air-Actuated Valves 0V/PH/0Hz/8.9A 0V/PH/0Hz/.A 0V/PH/0Hz/.A 0V/PH/0Hz/.A *Recommended for use with 0A breaker. 0V/PH/0Hz/8.A* 0V/PH/0Hz/8.9A VAC, VDC, or 0VAC,. Watts/Port SPACE REQUIREMENTS WALL-MOUNTED BOOSTER PUMPS (DEPTH X WIDTH X HEIGHT) -Pump Wall-Mount -Pump Wall-Mount -Pump Wall-Mount SPACE REQUIREMENTS FLOOR-MOUNTED BOOSTER PUMPS (DEPTH X WIDTH X HEIGHT) -Pump Floor-Mount -Pump Floor-Mount -Pump Floor-Mount x x 8 ( x x cm) x x 8 ( x x cm) x x 8 ( x 9 x cm) x x ( x x 8 cm) x x ( x 8 x 8 cm) x x ( x 8 x 8 cm) SPACE REQUIREMENTS GRUNDFOS PUMPS (DEPTH X WIDTH X HEIGHT) 0 GPM Grundfos Pumps 0 GPM Grundfos Pumps SPACE REQUIREMENTS FOR MCU, VFD, & MD PANELS (DEPTH X WIDTH X HEIGHT) Motor Control Unit VFD HD/XD Panels 7 x x ( x x 0 cm) 9 x x (9 x 8 x 07 cm) 9 x x ( x x 8 cm) x x 0 ( x x cm) 7 x x ( x 9 x 0 cm) WATER INLET LINES 0 GPM (7 LPM) Booster Pump 0 GPM (7 LPM) Grundfos Pump 0 GPM (0 LPM) Grundfos Pump ID. ID ID SOLUTION OUTLET LINES Up to. GPM (8. LPM). -. GPM (. - 7 LPM). GPM (0.8 LPM) GPM ( LPM) /8 ID (/ OD Polyflow*) / ID* /8 ID* / ID *Assuming line length is 0 ( m) or less. Refer to user page 8 for recommended size chart for other lengths. OUTLET CONNECTION FROM MANIFOLD 0 GPM VERTICAL GRUNDFOS PUMP 0 GPM VERTICAL GRUNDFOS PUMP. FNPT FNPT FLANGE TORQUE 0 or 0 GPM VERTICAL GRUNDFOS PUMP 7- ft-lbs MAX. WATER SOURCE TEMP. Recommended 0 F ( C) Max water temp 7 F (8 C) OPERATING WATER PRESSURE 00 PSI ( bar) Factory Set (Assumes 0 PSI (.8 bar) City Feed) WATER FILTRATION (SUGGESTED) 0 Micron AIR INLET LINE /8 OD Polyflow per Panel AIR INLET PRESSURE PSI (.-8. bar) Dry Air WATER SUPPLY MAX FLOW PER PORT Max Flow Per Hydra-Cannon Port Max Flow Per BAM Port PRESSURE TRANSDUCER (VFD) Pressure Range Set point Cord Length GPM GPM 0-00 PSI 00 PSI 7 Meter AIR OUTLET LINE /8 OD Polyflow per Application Hydra-Flex, Inc. 08 Page

4 POWER FROM WALL CONNECT TO PUMP x 0' SIGNAL WIRE TO AQUA-LAB INCLUDED x 8ft 0V / 80V PUMP POWER CORD INCLUDED WITH EACH PUMP PRESSURE TRANSDUCER CABLE PUMP STAND LOCATED WITHIN ' OF EACH HD/XD BOARD PRESSURE TRANSDUCER CABLE 0 FT WYE STRAINER INTEGRATED INTO OULET MANIFOLD LAYOUT DRAWING VFD BOX LOCATED WITHIN ' OF PUMP MOTOR AQUA LAB PHASE 80V OR 0V POWER IN PROVIDED BY OTHERS SIGNAL CONTROL CABLE INCLUDED 9. APPROX - IN X /8 CONCRETE ANCHORS INCLUDED WITH EACH PUMP STAND.7 x TAPCON ANCHORS INCLUDED FOR EACH HD/XD PANEL AQUA-LAB XD PANEL PER PRIMARY AIR REGULATOR x /8" POLY FLOW AIR INLET TUBING PROVIDED BY OTHERS (00psi MAX) x ' QUICK CHANGE FLEXIBLE HOSE WITH REGULATOR AND Y-STRAINER TO AQUA LAB WITH /" QUICK CONNECT AND BALL VALVE INCLUDED WITH EACH PANEL 0 GPM: "NPT HOSE BARB TO CONNECT TO WATER FEED PUMP INLET HOSE INCLUDED 0 GPM: " HOSE INLET PROVIDED VFD BOX 0 GPM PUMP ***Pump configuration will vary depending on specific order options. Hydra-Flex, Inc. 08 Page

5 PANEL DIAGRAM Solenoid Actuated Air Valves M Junction Block Home Run Cable (Goes to car wash controller for control voltage) Primary Air Regulator Gray M Cable (Goes to MCU/VFD) 7C 7B 7A Individual Air Regulators BAM Valve Triple Foam Manifold Hydra-Cannon Manifold Air Ports Solenoid Actuated Air Valves M Junction Block Home Run Cable (Goes to car wash controller for control voltage) Primary Air Regulator Gray M Cable (Goes to MCU/VFD) 7C 7B 7A Individual Air Regulators BAM Valve Triple Foam Manifold Air Ports Hydra-Flex, Inc. 08 Page

6 ESTIMATED INSTALLATION TIMELINE PRE-INSTALLATION WHO TASK EST. TIME DISTRIBUTOR & CUSTOMER DETERMINE LOCATION TO INSTALL EQUIPMENT HR PLUMBER INSTALL WATER SUPPLY LINE HR ELECTRICIAN INSTALL ELECTRICAL SUPPLY LINE HR TECHNICIAN LABEL ALL CONTROLLER RELAYS AT CONTROLLER HR TECHNICIAN RUN SOLUTION AND AIR LINES (IF NECESSARY) HR TECHNICIAN INSTALL AIR SUPPLY LINE HR INSTALLATION TOTAL LABOR HOURS HRS WHO TASK EST. TIME DISTRIBUTOR / TECHNICIAN HANG EQUIPMENT HR TECHNICIAN CONNECT WATER, AIR AND SOLUTION LINES HR TECHNICIAN CONNECT CONTROL LEADS TO MAIN CONTROLLER OR JUNCTION BOX HR DISTRIBUTOR/TECHNICIAN STARTUP (INJECTOR, METERING TIP AND NOZZLE SELECTION) HR DISTRIBUTOR/TECHNICIAN DOCUMENT CONFIGURATION HR POST INSTALLATION TOTAL LABOR HOURS 8 HRS WHO TASK EST. TIME DISTRIBUTOR MONITOR & RECORD PERFORMANCE HR / WK DISTRIBUTOR MAINTENANCE PER SCHEDULE OR AS NEEDED TOTAL HOURS SPENT TOTAL CUSTOMER TOTAL DISTRIBUTOR/TECHNICIAN TOTAL ELECTRICIAN HR HR HR Installation takes approximately ONE day. An electrician and a plumber are needed for half a day. TOTAL PLUMBER HR INSTALLATION INSTRUCTIONS General Skill Level Mechanical: Basic - mounting equipment Electrical: Advanced - three phase power and controls knowledge (local codes knowledge required) Plumbing: Moderate - principal supply line required Pneumatic: Basic- pneumatic utility connection required Chemical Knowledge: Moderate - chemical titrations required Tools & Equipment Needed: Drill with Phillips head Concrete drill bit /8 Concrete drill bit / Hammer Tape measure Level Utility knife Wire stripper Socket set Adjustable wrench Screw driver set Teflon tape Useful Tools: Amp Meter Volt Meter Hydra-Flex, Inc. 08 Page

7 UNPACKING When unpacking your Aqua-Lab HD/XD be sure not to discard the manual or any accessories. Inspect the shipment for any damage or missing components. If pumps are included with order, take care moving the pump(s). Utilize proper lifting technique and mechanical assistance if necessary. LOCATION & MOUNTING **If location was not identified during the Pre-Installation Process, make sure to consider the proximity to feed water, power supply, and the control cabinet as well as space near the system to store chemical containers. Mount base of panel from floor for easy injector access. ***See drawing in reference for general layout AQUA-LAB HD/XD (WALL MOUNT). Drill () / holes on the wall. /8 wide, 7 /8 tall.. Press Aqua-Lab HD/XD board tight against the wall.. Screw in / concrete screws with a washer. SYSTEMS WITH BOOSTER PUMPS & MCU PUMP ASSEMBLY - NEED TO BE WITHIN OF FURTHEST AQUA-LAB HD/XD PANEL. Drill /8 holes in wall for bottom slots (0 on center pump nose down,. on center pump nose sideways - dual stand).. Insert concrete anchors, set pump on bolts and tighten down.. Hold pump stand in place, drill top holes, insert anchors and tighten. MOTOR STARTER. Mount to the wall with appropriate anchors. SYSTEMS WITH VFD & GRUNDFOS PUMPS. Before bolting components down, ensure the water lines, electrical cables, etc. have enough length to connect.. Remove pump from packaging.. Locate pump in desired location.. Securely anchor pump to concrete floor.. Mount VFD to the wall. PNUMATIC CONNECTIONS Connect pre-run /8 OD poly feed line to push connect fitting on the side of the primary regulator. Connect /8 OD poly lines from arch to each port that will be foaming. **If there are unused air ports, counter-clockwise turn the individual line regulator until air no longer flows. Hydra-Flex, Inc. 08 Page 7

8 ELECTRICAL CONNECTIONS (HFI MOTOR CONTROL UNIT) a. Wire homerun control cables to car wash control panel. (See diagram on page for wiring schematic) Manifold position below designates which Hydra-Cannon port is associated to what color wire. Example: if you want Presoak to be on manifold port, connect the green wire to your controller relay for Presoak. 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!). 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!). Hydra-Flex, Inc. 08 Page 8

9 HFI STANDARD MCU & BOOSTER PUMP SECTION HFI BOOSTER PUMP & MCU (SINGLE SOURCE / SINGLE PUMP SHOWN) MCU WITH SMART RELAY Temperature Shutdown Light Smart Relay MCU WITH OUT SMART RELAY Current Switch Phase Disconnect Contactor Current Switch Phase Disconnect Contactor Thermal Overload Quick Connect Pump Plug Female Grey M Cables (Carry signal from M distribution block to motor starter that turns on the pump) Quick Connect 9 Cordset For Pump (Plugs Into Bottom Of Motor Starter) Temperature Switch Timer Relay Thermal Overload Quick Connect Pump Plug Female Back-up Pump Temperature Shutdown Relay Grey M Cables (Carry signal from M distribution block to motor starter that turns on the pump) Wye-Strainer Bypass Pressure Regulator Pump Outlet Feed Line To MD Panels FOR PART NUMBERS & DIAGRAMS - SEE PAGES 8- Hydra-Flex, Inc. 08 Page 9

10 HFI STANDARD MCU (WITHOUT SMART RELAY) & BOOSTER PUMP SECTION RELAY T T T T T T NO A 9 A TIMER RELAY RELAY TS TS 8 A B L L L NO A DISCONECT AC PHASE POWER IN FROM BREAKER PHASE /0VAC SINGLE SOURCE SINGLE PUMP 0009_RevC08 T T T P P T T T NO A 9 A TIMER RELAY RELAY TS TS A B L L L NO A 8 DISCONECT AC PHASE RELAY CONTROL VOLTAGE /0VAC SINGLE SOURCE SINGLE PUMP Hydra-Flex, Inc. 08 Page 0

11 HFI STANDARD MCU (WITHOUT SMART RELAY) & BOOSTER PUMP SECTION T T T T T T T T T NO A T T T NO A A A TIMER TIMER RELAY RELAY RELAY TS TS TS TS A A B A B L L L NO A L L L NO A DISCONECT PHASE RELAY 8 AC AC POWER IN FROM BREAKER RELAY RELAY PHASE /0VAC DUAL SOURCE DUAL PUMP 0000_RevC A A TIMER TIMER RELAY RELAY RELAY TS TS TS TS A 8 T T T T T T P P P T T T NO A T T T NO A 9 9 RELAY A B A B L L L NO A L L L NO A 8 DISCONECT AC AC PHASE RELAY RELAY CONTROL VOLTAGE /0VAC DUAL SOURCE DUAL PUMP Hydra-Flex, Inc. 08 Page

12 HFI STANDARD MCU (WITHOUT SMART RELAY) & BOOSTER PUMP SECTION RELAY T T T T T T NO A 9 A TIMER RELAY RELAY TS TS 8 A B L L L NO A DISCONECT DC PHASE POWER IN FROM BREAKER PHASE VDC SINGLE SOURCE SINGLE PUMP 0007_RevC08 T T T P P T T T NO A 9 A TIMER RELAY RELAY TS TS A B L L L NO A 8 DISCONECT DC PHASE RELAY CONTROL VOLTAGE VDC SINGLE SOURCE SINGLE PUMP Hydra-Flex, Inc. 08 Page

13 HFI STANDARD MCU (WITHOUT SMART RELAY) & BOOSTER PUMP SECTION 0008_RevC08 T T T T T T T T T T T T P P P T T T NO A T T T NO A 8 8 T T T NO A T T T NO A 9 9 A A A A TIMER TIMER RELAY RELAY TIMER TIMER RELAY RELAY RELAY RELAY RELAY TS TS TS TS A TS TS TS TS A RELAY 8 A B A B A B A B L L L NO A L L L NO A L L L NO A L L L NO A 8 8 DISCONECT DISCONECT DC DC PHASE AC AC PHASE POWER IN FROM BREAKER RELAY RELAY RELAY RELAY PHASE CONTROL VOLTAGE VDC DUAL SOURCE DUAL PUMP VDC DUAL SOURCE DUAL PUMP Hydra-Flex, Inc. 08 Page

14 HFI STANDARD MCU (WITH SMART RELAY) & BOOSTER PUMP SECTION T T T 9 9 Q Q Q Q T T T NO A SMART RELAY PS TS L L L NO A L N N I I I I I I I7 I8 DISCONECT AC PHASE RELAY POWER IN FROM BREAKER PHASE /0VAC SINGLE SOURCE SINGLE PUMP SMART_0009_RevA08 T T T P P 9 9 Q Q Q Q T T T NO A SMART RELAY PS TS L L L NO A L N N I I I I I I I7 I8 DISCONECT AC PHASE RELAY CONTROL VOLTAGE /0VAC SINGLE SOURCE SINGLE PUMP Hydra-Flex, Inc. 08 Page

15 HFI STANDARD MCU (WITH SMART RELAY) & BOOSTER PUMP SECTION T T T T T T Q Q Q Q T T T NO A T T T NO A SMART RELAY PS PS TS TS A L L L NO A L L L NO A L N N I I I I I I I7 I8 DISCONECT AC AC PHASE POWER IN FROM BREAKER RELAY RELAY PHASE /0VAC DUAL SOURCE DUAL PUMP SMART_0000_RevA08 T T T T T T P P P Q Q Q Q T T T NO A T T T NO A SMART RELAY PS PS TS TS A L L L NO A L L L NO A L N N I I I I I I I7 I8 DISCONECT AC AC PHASE RELAY RELAY CONTROL VOLTAGE /0VAC DUAL SOURCE DUAL PUMP Hydra-Flex, Inc. 08 Page

16 HFI STANDARD MCU (WITH SMART RELAY) & BOOSTER PUMP SECTION T T T 9 9 Q Q Q Q T T T NO A SMART RELAY PS TS L L L NO A L N N I I I I I I I7 I8 DISCONECT DC PHASE RELAY POWER IN FROM BREAKER PHASE VDC SINGLE SOURCE SINGLE PUMP SMART_0007_RevA08 T T T P P 9 9 Q Q Q Q T T T NO A SMART RELAY PS TS VOV OV I I I I I I I7 I8 L L L NO A DISCONECT DC PHASE RELAY CONTROL VOLTAGE VDC SINGLE SOURCE SINGLE PUMP Hydra-Flex, Inc. 08 Page

17 HFI STANDARD MCU (WITH SMART RELAY) & BOOSTER PUMP SECTION T T T 9 9 Q Q Q Q T T T NO A SMART RELAY PS PS TS TS A L L L NO A +VOV OV I I I I I I I7 I8 DISCONECT DC DC PHASE POWER IN FROM BREAKER RELAY RELAY PHASE VDC DUAL SOURCE DUAL PUMP L L L NO A T T T NO A 9 9 T T T SMART_0008_RevA08 P P P T T T 9 9 Q Q Q Q T T T NO A SMART RELAY PS PS TS TS A L L L NO A +VOV OV I I I I I I I7 I8 DISCONECT DC DC PHASE RELAY RELAY CONTROL VOLTAGE VDC DUAL SOURCE DUAL PUMP L L L NO A T T T NO A 9 9 T T T Hydra-Flex, Inc. 08 Page 7

18 FEED WATER CONNECTION **PRIOR TO CONNECTION, ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR MINUTES Connect pre-run main water supply line to pump inlet with hose supplied. Single operating pump: MNPT HFI BOOSTER PUMP SECTION Dual operating pump: -/ MNPT START UP BOOSTER PUMPS!WARNING! PUMP MUST BE PRIMED BEFORE OPERATION. FLUSH Make sure water supply to pump is turned on. Open ball valve and direct toward a drain or container to remove the majority of the air from the pump until a steady stream of water is flowing (approx. min). Then close the ball valve. 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 T, T, and T. 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.. CHECK ROTATION Open Aqua-Lab Motor Control Unit (MCU) and ensure phase disconnect is on. (Note: Door will not open with disconnect on. Use a / 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 ).!WARNING! - ELECTRIC SHOCK HAZARD. HIGH VOLTAGE PRESENT INSIDE MOTOR CONTROL UNIT - USE CAUTION! Start the pump momentarily by depressing the center of the contactor (image ). Image Image Hydra-Flex, Inc. 08 Page 8

19 HFI BOOSTER HFI BOOSTER PUMP PUMP SECTION!WARNING! RUNNING THE PUMP BACKWARD WILL CAUSE CATASTROPHIC SYSTEM FAILURE! ENSURE THAT PUMP ROTATION IS CORRECT (image ) as indicated by the arrow on the casting of the pump and that 00 psi can be reached. If pump cannot regulate to 00 psi, remove pump motor cover and look at shaft to confirm correct rotation. Verify pump inlet pressure remains positive when running.. CLOSE CABINET Turn on phase disconnect, if high temp switch is present, push to start (Image ).. PURGE BYPASS Start the pump and slowly open ball valve until it is wide open. Allow to run for 0 seconds to flush lines and then close valve.. CONNECT Connect the pump outlet line to the manifold and open ball valve.. DOUBLE CHECK Confirm that the pump can obtain 00 psi while firing solenoids and that the pump housing (stainless steel tube) is cool to the touch after a minute in operation. If housing is hot or noisy, pump did not prime correctly. If pump does not prime, repeat steps -. If not at 00 psi and the pump is correctly rotating you may need to adjust the bypass regulator to obtain 00 psi (Image ). Verify pump prime hours after operation to ensure prime held. Pay close attention to the temperature of the pump shaft, the whole stainless steel area (Image ) should be the same temperature. If it starts getting hotter than the supply water or greater than 7, then it is likely that the pump did not prime correctly which WILL CAUSE DAMAGE TO PUMPS. The motor housing (painted portion) will be hot during operation. Image Image 7 Image ******************(HFI supplied motor starter)****************** b. Connect the gray M cables hanging out of the motor starter box to port 8 PUMP on the black M 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 T, T, and T. Make sure to follow all applicable electrical codes. Hydra-Flex, Inc. 08 Page 9

20 HFI GRUNDFOS PUMP SECTION HFI GRUNDFOS PUMP & VARIABLE FREQUENCY DRIVE (VFD) Fan Fuses & Transformer Fan Filter VFD Main Power Fuses Current Switch Fan M Connections To Junction Block Gray Cord For Pressure Transducer Electric Disconnect Incoming Power Pump Motor Pump Power Cord, To Be Wired To VFD Motor Stool For Lifting Vent Cap To Prime pump Pump Outlet (/ FNPT for 0 GPM, FNPT For 0 GPM) Embossed Arrow For Motor Direction Pump Inlet (. ID Hose For 0 GPM, ID Hose For 0 GPM) Location For Pressure Transducer, Temp Switch, Pressure Gauge. (QTY : / FNPT) Wye Strainer Screen (Inside Manifold, Remove Plug To Clean Strainer Screen) FOR PART NUMBERS & DIAGRAMS - SEE PAGES -7 Hydra-Flex, Inc. 08 Page 0

21 HFI GRUNDFOS PUMP SECTION VFD WIRING DIAGRAM (FOR FLOOR MOUNTED GRUNDFOS PUMP) DC WIRING - = Current Switch - 7 = Pressure Transducer Block Block - 0 = Temp Switch or Jumper Shield MOTOR U V W MAINS U V W 9 0 Current Switch 0 Pump OV OV V 7 0 OV OV V V NC AC WIRING - = Current Switch - 7 = Pressure Transducer - 0 = Temp Switch or Jumper Block Block MAINS U V W MOTOR U V W 7 8 Current Switch 9 0 Power From Fuses Pump Ground S+ S+ S+ S- S- S- NC NC NC V V OV OV 0 7 Shield 7 V OV OV 0 0 NC S- S- S- S+ S+ S+ Jumper Jumper Jumper Jumper Aqua-Lab Panel Aqua-Lab Panel Cap Brown Wire Optional Temp Switch NC Transducer: Brown = V Blue = 7 Shield = Green 0 Power From Fuses Ground Jumper Jumper Jumper Jumper Optional Temp Switch Transducer: Brown = V Aqua-Lab Panel Aqua-Lab Panel Blue = 7 Shield = Green Cap Brown Wire Hydra-Flex, Inc. 08 Page

22 LOC REM? STOPS START HFI GRUNDFOS PUMP SECTION GREY M CABLE DIAGRAM TWO PANELS (SINGLE FLOOR MOUNT GRUNDFOS PUMP & VFD) VFD Home Run Cable To Power PH To Car Wash Controller Gray Wire Gray Wire Note: Not all gray wires will be used. Pressure Sensor Wire Grundfos Pump Pressure Sensor Water Outlet Water Inlet Hydra-Flex, Inc. 08 Page

23 HFI GRUNDFOS PUMP SECTION START UP (SYSTEMS WITH VFD & GRUNDFOS PUMPS):. Slide in hex nuts from plumbing outlet manifold into slots on pump housing. Fasten outlet manifold to pump housing. Torque bolts to ~0 foot pounds. Ensure gasket is located correctly.. Verify that the pump voltage matches the site voltage that will be supplied to power the pump. There is a voltage label on the pump cord indicating which voltage the pump is wired for. Motors are rated for + 0% of the rated voltage on the motor name plate.. Route power from site to VFD box. Make sure that the site power being supplied matches the VFD voltage. Note: Do not run pump power cord within ft of sensitive electronics. Route in independent conduit to prevent signal interference. CAUTION: DO NOT APPLY 80V TO A 0VAC VFD.. Route pump power cord to VFD. Slide Nuts Into Frame Fasten outlet manifold to pump housing Pump Power Cord White to U, Red to V, Black to W, Ground to Grounding screw. Route water to pump. a. Note: for 0 GPM pump, do not plumb any elbows or bends within 0 inches of the pump inlet. b. Note: for 0 GPM pumps, do not plumb any elbows or bends within inches of pump inlet. 7. Route pump outlet to Aqua-Lab HD/XD panel. Main Site Supply Power White to L, Red to L, Black to L 8. Prime the pump by loosening the vent plug located at the top of the pump. Air will purge through the vent hole. Pump is primed once water begins to flow out of the vent. Tighten vent cap plug. 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. Loosen Priming Vent To Purge Air Pump Is Primed Once Water Begins To Come Out. Close Vent By Tightening Plug 9. Attach gray pressure transducer cable to pressure transducer. 0. Attach remaining gray signal cords to Aqua-Lab HD/XD M junction blocks positions six and 8B. a. Note: The VFD control box has M 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) Hydra-Flex, Inc. 08 Page

24 . Ensure VFD is in the REM Mode by using the keypad on the front face of the VFD.. SEE PAGE FOR INSTRUCTIONS ON WIRING YOUR VFD. YOUR VFD MUST BE WIRED IN ORDER FOR YOU TO VERIFY ROTATION. Verify Correct Rotation (in REM MODE): Pulse the pump on and off by sending a signal from the car wash controller for a chemical function to turn on. Examine the fan by looking downward onto the pump. Verify that the fan is spinning in the same direction as indicated on the motor casting. 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 U with V as shown in the image above in section. CAUTION: DO NOT WORK INSIDE VFD BOX UNTIL 0 MINUTES AFTER POWER DOWN.. Send signal from carwash controller to Aqua-Lab panel to turn on pump, verify that PSI water is supplied to the Aqua-Lab panel. Use the up and down arrows on the keypad to increase/decrease pressure. VFD MODES FAULTS Press loc/rem Button Until REM Is Shown In The Top Left Of Screen Direction On Motor Casting Indicating Correct Direction The VFD has the following fault protections to keep the pump and system safe. See table below. FAULT TYPE FAULT CAUSE SCREEN READ OUT Low Inlet Pressure (FAULT ) High Temperature (FAULT ) HFI GRUNDFOS PUMP SECTION Remote Mode: This takes a signal from a car wash controller to turn on a chemical function which then initiates the VFD to start the pump. To use REM mode, press the loc/rem button on the left of the key pad until REM appears on the top left of the screen. Send a signal from the carwash controller to activate the pump. Use the up and down arrows on the keypad to increase/decrease pressure. SAFETY CAUTION: WAIT 0 MINUTES AFTER POWERING DOWN THE VFD BEFORE WORKING INSIDE THE BOX. THE VFD CONTAINS LARGE CAPACITORS AND 0 MINUTES IS NEEDED TO ALLOW THE CAPACITORS TO SAFELY DISCHARGE.. No water supplied to pump inlet.. Blown fuse on incoming power supply.. Panel flow set up exceeds pump performance curve (reduce injector sizes).. Hose rupture.. Pump running at low pressure for more than minute.. If temperature switch is wired in and the temperature exceeds switch set point, the temperature switch will fault out.. If the temperature switch is not installed make sure that there is a solid jumper between terminal block V and terminal block 0. LOC REM? Hydra-Flex, Inc. 08 Page LOC FAULT FAULT INLET LOW RESET STOPS REM FAULT FAULT EXT FAULT RESET EXIT TART LOC REM? STOPS EXIT TART

25 APPENDIX INITIAL INJECTOR SETUP (Based on field experience this is HFI s recommended starting point). Using the recommended starting point (Page ) or the target flow rate and the chemical dilutions chart (appendix Page ) install the appropriate injector into each port.. Connect pre-run solution lines to each injector with the supplied check valve and push connect fitting. a. Be sure to use Teflon tape when connecting the injector to the check valve and push connect fitting to ensure there are no leaks. b. Do not over tighten poly fittings or they may crack (HAND TIGHTEN ONLY).. Connect ¼ poly lines from each chemical container to the hose barb on the appropriate injector. 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.. Metering tips will need to be installed to set dilution ratio (see appendix Page for ratio charts to determine tip.) Your Aqua-Lab HD/XD panel was design with Tri-Foam capability the below instructions will show you how to setup your triple foam. Your triple foam has been setup from the factory to be in the last port (furthest left). Insert your triple foam manifold into that position with your selected injectors already inserted. TRIPLE FOAM SETUP On the topside of the panel the regulators will control the air to each of your triple foam colors. Insert your air lines to the arch into the bulkhead fittings on the side of the panel. The bulkhead will be the airlines for each color. C B A 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. B A C Hydra-Flex, Inc. 08 Page

26 OPTIMIZING THE SYSTEM CONSISTENTLY ACHIEVE THE DESIRED CLEANING AND PRESENTATION/ PERFORMANCE USING THE LEAST AMOUNT OF CHEMICAL AND WATER INJECTORS VS. METERING TIPS VS. NOZZLES THE KEY TO OPTIMIZING THE SYSTEM IS THROUGH TRIAL AND ERROR. DON T BE AFRAID TO TRY THESE STEPS TO ACHIEVE YOUR IDEAL PERFORMANCE What do injectors do? Increases or decreases the amount of water in the solution. What do metering tips do? Increases or decreases the amount of chemical in the solution. What do nozzles do? Determines the pattern and back pressure of the solution. 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) No chemical Check vacuum/back-pressure of injector for clogging (see page for Injector Vacuum Check Instructions or page 9 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) NOZZLE SETUP Using the recommended starting point (appendix page ) install the recommended nozzles. This may involve removing and plugging some ports. Due to the lower water usage determined by the injector of the Aqua-Lab you will need to match the flow of the application device to the injector. Setup the nozzle spray patterns to paint the car - slightly overlapping each other. Hydra-Flex, Inc. 08 Page

27 0 8 INJECTOR FLOW 00 PSI (GPM) INJECTOR FLOW 00 PSI (GPM) MINIMUM NUMBER OF NOZZLES NECESSARY WITHOUT FOAMING AIR (Assuming <0 PSI line loss and ~ 0 PSI at the nozzle) SPRAY NOZZLE SIZE #.0 #.0 #.0 #.0 #.0 # 7.0 # 8.0 # 9.0 # MINIMUM NUMBER OF NOZZLES NECESSARY WITH FOAMING AIR (Assuming <0 PSI line loss and ~ 0 PSI at the nozzle) SPRAY NOZZLE SIZE #.0 #.0 #.0 #.0 #.0 # 7.0 # 8.0 # 9.0 # Elbows/Pipe Fittings Elbows and other pipe fittings add back pressure by causing the fluid to change direction and thus changing the fluid s momentum. Try to find simpler ways to route your fluid without elbows. Line Length Longer lines add back pressure due to the inherent resistance caused by friction. See if you can reduce the line length or increase the inside diameter. CHEMICAL USAGE MEASURING VERIFY TITRATION OF CHEMICALS BEFORE PROCEEDING. Set up lab scale with small bucket of chemical to be measured.. Put the suction line into the bucket.. Run the application being tested to prime the line. (All air bubbles must be removed for accuracy.). Record the Initial Weight from the scale. (Taring the scale with weight on the scale can affect accuracy.). Run the application for vehicle (or manually for the same amount of time it would be on for vehicle).. Record the Final Weight from the scale. 7. Subtract the Initial Weight from the Final Weight to determine the weight of used product. 8. Divide the Per Car Weight in grams by the specific gravity of the chemical to determine the milliliters of chemical used per vehicle. 9. Repeat for each chemical application. Hydra-Flex, Inc. 08 Page 7

28 RECOMMENDED MAINTENANCE THE RECOMMENDED SERVICE AND MAINTENANCE ON THE AQUA-LAB SYSTEM ARE AS FOLLOWS. Monthly Check/drain primary air regulator/filter separator. Check water filter and replace as needed (if installed). Check and clean wye strainer. Semi-Annually Check and replace injector metering tips. Inspect and replace chemical lines as needed. Ensure lines are tightly secured to injector hose barbs, clip off old hose as needed that was stretched by hose barb. Annually Clean water regulator. Inspect motor starter for corrosion, if identified order replacement/spare parts. - Years Inspect and replace injectors. Replace water valves. Replace main pressure regulator. AIR OPERATED VALVE REPLACEMENT. Shut off the ball valve to Hydra-Cannon manifold.. Disconnect air line from front of valve.. Unscrew quick connect fitting by hand (DO NOT LOSE BLACK WASHER).. Unscrew valve assembly from the Hydra-Cannon manifold.. Screw new valve into manifold until hand tight and threaded pilot port is facing forward.. Remove the cap from pilot port and thread in quick connect fitting to front of valve HAND TIGHT ONLY. 7. Push air line back into fitting. 8. Open the ball valve to the Hydra-Cannon manifold. Unscrew from manifold using this portion of valve BAM VALVE REPLACEMENT. Shut off the water supply ball valve to the BAM manifold.. Disconnect air line from front of manifold.. Remove spring clips from assembly that are adjacent to valve being replaced.. Unbolt valve assembly from the panel.. Remove valve from assembly.. Install new valve into assembly ensuring correct orientation. 7. Reinstall spring clips and bolt valve assembly to panel. 8. Push air line back into fitting. 9. Open the water supply ball valve to the BAM manifold. Hydra-Flex, Inc. 08 Page 8

29 PUMP ISSUES TROUBLESHOOTING PROBLEM POTENTIAL CAUSES SOLUTIONS Pump Operates, But Only Delivering 00-0 Psi Incorrect motor rotation Pump not primed Missing of phases Reverse rotation by interchanging two leads. See priming instructions. Wire according to diagram/check breaker (turn off on back). Pump Operates, But Delivers Little Or No Water Overheat Light On Pump Will Not Start Or Run At Full Speed Inadequate water supply Undersized piping Leak on the inlet side Worn or defective pump parts Inlet temp too high Injector flow too low Constant hot not connected Blown fuse or circuit breaker Defective motor starter contactor Thermal overload set too low/tripped Incorrect motor voltage Defective motor Check pressure on inlet side of pump to be sure positive pressure is maintained. Replace with larger piping. Make sure connections are tight. Replace worn parts or entire pump, clean parts if required. Reduce inlet temp to 0 F Max, injector flow to 0 GPM max. Increase continuous flow to at least / GPM. Make sure constant control voltage is supplied in car wash controller. Could be due to blown pump motor. Try to turn breaker back on or replace fuse. If breaker trips after trying to fire motor it is most likely burned out. Replace with new motor and pump. Replace motor starter contactor. Adjust setting on thermal overload to match voltage. Voltage must be within 0% of motor rated voltage. (Check that pump is wired for correct voltage.) Replace motor. phase disconnect turned off Turn disconnect on. Pump components damaged Current Sensor not seeing any current Replace worn part or entire pump. Turn on one valve and verify red light blinks fast, verify at least 0 wraps of wire around current sensor. INJECTOR ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Injector Is Not Drawing Chemical - Passes Vacuum Pressure Check No Flow From Injector Injector Is Not Drawing Chemical - Fails Vacuum Pressure Check Clogged chemical feed Valve malfunction, valve not opening Clogged injector No water supply Too much back pressure on injector Clogged injector check valve Clogged injector nozzle Defective injector Product specific - Sonny s Rain Bar Manifold inlet clogged (rare) Check chemical hose, foot valve, metering tip, and hose barb for debris or clogs. Ensure minimum 0 psi on primary air regulator, ensure valve receiving signal. Remove injector and blow out debris with compressed air. Check that the system has a supply of water. Clean or replace downstream check valves, increase nozzle size or quantity, use larger tubing, or use smaller flow injectors. Blow compressed air through the chemical hose barb on the injector to remove debris. Remove injector and blow out any debris with compressed air. Replace injector. Remove elbow at inlet to foam generator and remove nozzle. Remove end fittings and retention rod. Clean out inlet holes to allow full flow. Injector stainless steel disintegrating Strong hydrofluoric acid Call Hydra-Flex and order composite version of injectors. Hydra-Flex, Inc. 08 Page 9

30 PRESSURE REGULATOR ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS System Won t Regulate Up To 00 Psi FLOW / ARCH ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Flow At Arch Is Too Low VALVE ISSUES Pump not primed Debris in regulator Motor rotation incorrect Opening too many valves at once Defective check valve (if applicable) Defective Regulator Defective Pump Pressure Transducer is set incorrectly or is broken Pressure Transducer cable is loose or damaged Incorrect injector flow rate selection System pressure too low Foam generator plugged Downstream plumbing restrictive Replace with larger injector Ensure system pressure is set at 00psi Ensure cleaned and clear PROBLEM POTENTIAL CAUSES SOLUTIONS Follow priming instructions. Remove regulator and clean out debris. Verify rotation / switch leads. System is limited by size of pump and size of injectors, increase flow by adding secondary pumps or reduce size / number of injectors open. Replace check valve. Replace regulator. Replace Pump. Refer to Pump Manual to verify transducer setting or replace transducer. Ensure good connections or replace cable. Increase size of plumbing / tubing, ensure check valves are cleaned or new, reduce elbows in line or other turns that would restrict Valve Will Not Open Valve Leaks Air Or Water Out Top Valve Remains Open After Signal Is Off Air pressure too low Internal valve o-ring jammed / twisted Internal o-ring seal damaged / worn Manifold pressure is above 0 psi Air exhaust muffler is clogged Ensure primary air regulator reading at least 0 psi, turn up to 80-90psi if possible and check again. Remove valve from manifold, Carefully remove top of valve (caution under high spring pressure) push white piston up with small allen wrench from opposite end and check o-ring condition. Replace and lubricate if needed. Remove valve from manifold, Carefully remove top of valve (caution under high spring pressure) push white piston up with small screwdriver from opposite end and check o-ring condition. Replace with 08 & 008 Viton O-ring and lubricate with Dow valve lube. Reduce pressure to manifold to 00 psi operating pressure. Replace exhaust muffler. VFD ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Low Inlet Pressure (FAULT ) Valve Leaks Air Or Water Out Top High Temperature (FAULT ) No water supplied to pump inlet. Blown fuse on incoming power supply. Panel flow set up exceeds pump performance curve. Water pressure is less than 00 psi for longer than minute. If temperature switch is wired in and the temperature exceeds 80 F, the temperature switch will fault out. If a temperature switch is not installed, false signal to VFD. Verify water supplied to pump is sufficient. Confirm correct electrical supply and connections. Ensure total injector flow is less than pump system can provide. Reduce injector size(s) if needed. Check system for leaks or ruptured hoses. Ensure inlet water temperature is less than 0 F. Ensure a solid jumper between terminal block V and terminal block 0 in the control box. Hydra-Flex, Inc. 08 Page 0

31 INJECTOR OPTIMIZATION TOOL BACKGROUND: This tool is for initial setup and troubleshooting of Chem-Flex Injectors and an Aqua-Lab HD/XD Chemical Dispensing System. In order for the injector to work properly and draw chemical this gauge must be in the GREEN section when installed immediately after an injector that is running. If the gauge is in the red you will either see: intermittent chemical, no chemical draw, or chemical being applied at a very low pressure. Back pressure refers to the pressure in the solution output line. Excessive back pressure is the main reason that injectors will not draw. If there is ever any concern to why an injector is not drawing chemical, the best and easiest way to diagnose the problem is to check the back pressure. See instructions below: STEPS:. Plug the optimization tool into the outlet line of injector and connect solution output line.. Turn on function from car wash controller to actuate Hydra-Cannon valve such that fluid is flowing through both the injector and injector optimization tool and out to the applicator.. Read injector optimization tool.. If the gauge is in the RED ZONE the back pressure of the outlet line is either too low or too high. See steps below to correct. Hydra-Cannon Valve Injector Injector Optimization Tool Solution Output Line Chemical Draw Line Chemical Bucket BACK PRESSURE TOO HIGH (UPPER RED SECTION): (Back Pressure May Be Affected By One Or Several Of These Things). Foam generators are clogged/degraded. Clean or replace media in generator.. Injector flow size is too large. Go down an injector size (less GPM).. Nozzle size on the arch is too small. Go up in nozzle size.. Check valves are dirty and or failing. Clean or replace check valves.. There is a kink in the line or excess fittings (elbows and reducers increase the back pressure). Check line and replace any kinked sections. Try to reduce fittings.. ID of tubing going out to the tunnel is too small. Go up a size in inside diameter. 7. Check valves have too high of cracking pressure. Replace check valve with lower pressure check valve. 8. Clean foot valve. BACK PRESSURE TOO LOW (LOWER RED SECTION): (Back Pressure May Be Affected By One Or Several Of These Things). Injector flow too low. Increase injector size.. Nozzle size too large. Reduce nozzle size. Hydra-Flex, Inc. 08 Page

32 INJECTOR VACUUM CHECK (FOR TROUBLESHOOTING INJECTORS). At the Chem-Flex injector, remove the chemical feed line from the injector hose barb.. Attach the tubing of the vacuum gauge to the Chem-Flex hose barb (Image A).. With the pump(s) on, manually activate the chemical that is to be tested at the main car wash control cabinet. An injector that is working properly will have a reading greater than or equal to ( ) 0 in Hg.. If vacuum reads <0 in/hg (image B), remove solution metering tip (image C) and retest. a. If retest vacuum reads >0 in/hg (image D), The solution metering tip is clogged. Replace the metering tip. b. If Retest vacuum reads <0 in/hg, continue to STEP. Remove a nozzle on the arch or the chemical feed line from the foam generator and retest vacuum. a. If retest vacuum reads >0 in/hg, back pressure is being created. Continue to STEP. b. If back pressure is not still not being created try these steps and retest after each:. Clean nozzle tips.. Loosely replace media in foam generator. Do not over pack.. Decrease air pressure for foaming. D. Try smaller injector (this will produce less flow and thus less back pressure). c. If retest vacuum reads <0 in/hg, replace injector and retest. If vacuum continues to read <0 in/ Hg, call your service provider.. Repeat steps - for each chemical lane that a vacuum reading is needed for. 7. Once testing is complete, turn off the Aqua-Lab HD/XD pump from the main car wash control cabinet. HFI MCU HIGH TEMP SHUTDOWN RESTART INSTRUCTIONS. A B C.. Close ball valve on panel and quick disconnect high pressure water line. *** Purge pressure before disconnecting (pressure gauge to read 0 PSI before disconnecting).. Point hose to drain and open ball valve to purge hot water and cool pump for several minutes (USE CAUTION).. When pump is sufficiently cooled close ball valve, reconnect hose, open ball valve and press red button on MCU to restart.. Determine why system overheated. See manual for troubleshooting (page 9 Overheat Light On). Hydra-Flex, Inc. 08 Page

33 REFERENCE - CHEMICAL DILUTION RATIOS NOTE: Dilution ratios given 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. 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. (Assumes feed pressure of 00 PSI ( bar)) #8- METERING TIPS Flow Rate (GPM) at 00 PSI Injector Color White Yellow Tan Red Orange Gray Blue Light Blue Light Green Pink Purple Dark Green Black Black Black Black COPPER : 7 : 0 : : 9 : 8 : 0 : 8 : 98 : 9 : 79 : 88 : 07 : 09 : 8 : : 9 PUMPKIN : : 8 : 9 : : 8 : 8 : 98 : 9 : : 7 : 77 : 9 : : 8 : 0 : 0 BURGUNDY : : 7 : 97 : : 07 : 0 : 7 : : 9 : 7 : 90 : 8 : : 70 : 97 : 9 LIME : 8 : 7 : 8 : 00 : 8 : 70 : 07 : : 7 : 8 : : 7 : 988 : : 8 : 98 TAN : 8 : 7 : 8 : 00 : 8 : 70 : 07 : : 7 : 8 : : 7 : 8 : 0 : 8 : 7 ORANGE : : : : 78 : 7 : 9 : : 9 : : : 7 : : 7 : 87 : : TURQUOISE : 7 : : : : 9 : : : 8 : 97 : 0 : 7 : : : 7 : 88 : 099 PINK : : : : : 8 : 9 : 98 : 0 : : 9 : 88 : : 7 : 7 : 70 : 78 LIGHT BLUE : : 7 : : : 7 : : : 9 : 98 : : : : 8 : 0 : 8 : 7 BROWN : 0 : : : 8 : : 8 : 9 : 8 : 88 : 0 : : 0 : 70 : 8 : 08 : 07 RED : : 7 : : : : : : 9 : 80 : 9 : : 0 : : 0 : 7 WHITE : : : : : : : : : 7 : 88 : 08 : 80 : : 7 : GREEN : : : 0 : 8 : 7 : 8 : : : : 7 : 9 : 0 : 0 : : 00 BLUE : 0 : : 7 : : 0 : : : : : : 77 : : : 8 : YELLOW : 9 : : : 0 : : 0 : : : : : 80 : 00 : 0 : 8 BLACK : 0 : : : 7 : : : 8 : : 0 : : 77 : 9 : PURPLE :. : 8. : 9 : 0 : : : : 7 : : : 9 : : 7 GRAY :. :.7 :.9 : 7. : 9.9 : 0 :. : : : : 0 : : OPEN :.9 :. :. :.0 :. :. : 7. : 8. : 0 : : : 8 :.00 : : 0 : 7 : 00 : 09 : 0 : : : 0 : 8 : : : 807 : 009 : 070 : : 8 : : : 7 : 089 : : : 0 : 7 : 0 : : 99 : 80 : 77 : 8708 : : 0 : 08 : : : : 8 : 9 : 8 : 778 : 898 : 89 : 8 : : : 98 : : 8 : : 7 : 9 : 9 : 9 : 7 : : 8 : 7 : 8 : 8 : : 9 : 9 : : 9 : 9 : 78 : 8 : 7 : 7 : : 87 : 9 : 8 : 09 : 07 : 90 : 7 : 8 : 0. : : 8 : 0 : : 0 : 7 : 0 : 8 : 0 : : : 78 : 088 : 0 : : 00 Spiral Plug Length Metering Tip /8 polyflow (LLDPE) tubing is required to ensure a seal between the tube wall and the spiral plug. Hydra-Flex, Inc. 08 Page

34 RECOMMENDED SETUP STARTING POINTS For optimal performance, match the flow of the injector to the flow of the nozzles or applicator. This may involve changing nozzles and/or removing or plugging some ports. See below for recommended set up starting points. APPLICATOR Scent Dispenser CTA Nozzles (For Showerhead, See Below) Foam Stick Mitter/Wrap Nozzles Undercarriage/Rust Inhibitor V Jet Or Flat Fan Nozzle Arch K Nozzle Arch K Nozzle Arch INJECTOR(S) PART NUMBER/COLOR (.0 GPM) (.8 LPM) (.0 GPM) (.8 LPM) (. GPM) (.7 LPM) (. GPM) (.7 LPM) (.0 GPM) (7. LPM) (. GPM) (8. LPM) (. GPM) (8. LPM) (. GPM) (. LPM) Hockey Puck Row Of Holes (0.7 GPM) (.8 LPM) Rows Of Holes (.0 GPM) (.8 LPM) Rows Of Holes (. GPM) (.7 LPM) Showerhead Row Of Holes (.0 GPM) (.8 LPM) Rows Of Holes (. GPM) (.7 LPM) Rows Of Holes (.0 GPM) (7. LPM) Rain Bar Row Of Holes (. GPM) (8. LPM) Rows Of Holes (. GPM) (. LPM) Rows Of Holes (. GPM) (0.8 LPM) Low Foam Curtain - Choose Foam Accessory Based On # Of Inputs/Foam Generators Duo-Foam With (X) (. GPM) (. LPM) Triple-Foam With (X) (. GPM) (8. LPM) Foaming Air: Start at PSI (adjust based on unique application) CHEM-FLEX INJECTOR PART NUMBERS INLET CONNECTION PC STANDARD (QUICK CONNECT) PC COMPOSITE (QUICK CONNECT) OUTLET CONNECTION /8 MNPT /8 MNPT FOR USE WITH AQUA-LAB MODEL(S) MD MD COLOR FLOW 00 PSI ( bar) SINGLE BARB DUAL BARB SINGLE BARB DUAL BARB White 0. GPM (.0 LPM) Yellow 0.0 GPM (.9 LPM) Tan 0.7 GPM (.8 LPM) Red.00 GPM (.8 LPM) Orange.0 GPM (.7 LPM) Gray.00 GPM (7. LPM) Dark Blue. GPM (8. LPM) Light Blue.00 GPM (. LPM) Light Green. GPM (. LPM) Pink.7 GPM (. LPM) Purple.0 GPM (7.0 LPM) Dark Green.0 GPM (0.8 LPM) Hydra-Flex, Inc. 08 Page

35 *For exclusive use with Aqua-Lab Chemical Dispensing Systems. SPECIFICATIONS Max Pressure Inlet NPT up to 000 PSI (9 bar) PC Standard up to 00 PSI ( bar) PC Composite up to 0 PSI (7 bar) Max Pressure Outlet PSI ( bar) Temperature Range Maximum Wrench Torque F - 0 F (. C - 0 C) Hand Tighten Only 0 ft-lbs PC CHEM-FLEX INJECTOR PART NUMBERS INLET CONNECTION OUTLET CONNECTION FOR USE WITH AQUA-LAB MODEL(S) PC* / MNPT XD, HD COLOR FLOW 00 PSI ( bar) SINGLE BARB Black 8.00 GPM (0. LPM) 88 Black 0.0 GPM (7.9 LPM) 8877 Black.0 GPM (. LPM) 888 Black.0 GPM (.8 LPM) 8807 *For exclusive use with Aqua-Lab Chemical Dispensing Systems. SPECIFICATIONS Max Pressure Inlet / Outlet Up to 0 PSI (7 bar) Maximum Wrench Torque (PC) Hand Tighten Only (0 in-lbs) Temperature Range F - 0 F (. C - 0 C) Maximum Wrench Torque (PC) Hand Tighten Only (0 in-lbs) PRESSURE LOSS IN RUN LENGTH GREEN = GOOD YELLOW= USE CAUTION RED = NOT RECOMMENDED All solution line tubing should be selected for 0 PSI or less of pressure loss. *0 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. /8 ID BRAIDED Run Length Flow Rate (GPM) at 00 PSI INJECTOR Injector Color White Yellow Tan Red Orange Gray Nozzle Size 0.09 (0.7 mm) 0.00 (.0 mm) 0.0 (. mm) 0.07 (. mm) (.8 mm) 0.08 (. mm) Dark Blue 0.08 (. mm) Light Blue 0.09 (. mm) Light Green (. mm) Pink 0.0 (.9 mm) Purple 0.7 (.9 mm) Dark Green 0. (. mm) 0 PSI PSI PSI PSI PSI PSI PSI PSI 7 PSI 9 PSI PSI* 8 PSI* PSI PSI PSI PSI PSI PSI PSI PSI PSI 8 PSI PSI* PSI* 00 PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI 9 PSI PSI* 7 PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI 7 PSI 9 PSI 0 PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI Hydra-Flex, Inc. 08 Page

36 / ID BRAIDED Run Length Flow Rate (GPM) at 00 PSI INJECTOR Injector Color White Yellow Tan Red Orange Gray Blue Nozzle Size 0.09 (0.7 mm) 0.00 (.0 mm) 0.0 (. mm) 0.07 (. mm) (.8 mm) 0.08 (. mm) 0.08 (. mm) Light Blue 0.09 (. mm) Light Green (. mm) Pink 0.0 (.9 mm) Purple 0.7 (.9 mm) Dark Green 0. (. mm) 0 PSI PSI PSI PSI PSI 9 PSI PSI* 8 PSI* PSI 7 PSI PSI PSI PSI PSI PSI PSI PSI 8 PSI 9 PSI PSI* 8 PSI* PSI 0 PSI 7 PSI 00 PSI PSI PSI PSI PSI 7 PSI 8 PSI PSI* PSI* 8 PSI* PSI PSI 7 PSI PSI PSI PSI PSI PSI PSI 9 PSI PSI* PSI* 8 PSI* PSI 0 PSI PSI PSI PSI PSI PSI PSI PSI 8 PSI 9 PSI PSI* 8 PSI* PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI 9 PSI /8 ID, / OD POLY TUBE Run Length Flow Rate (GPM) at 00 PSI INJECTOR Injector Color White Yellow Tan Red Orange Gray Blue Nozzle Size 0.09 (0.7 mm) 0.00 (.0 mm) 0.0 (. mm) 0.07 (. mm) (.8 mm) 0.08 (. mm) 0.08 (. mm) Light Blue 0.09 (. mm) Light Green (. mm) Pink 0.0 (.9 mm) Purple 0.7 (.9 mm) Dark Green 0. (. mm) 0 PSI PSI 7 PSI PSI* PSI PSI PSI 7 PSI 88 PSI PSI PSI 9 PSI PSI PSI PSI 9 PSI 8 PSI* 0 PSI 7 PSI PSI 7 PSI 0 PSI 9 PSI 00 PSI 00 PSI PSI PSI 7 PSI PSI* PSI 8 PSI 0 PSI PSI 77 PSI 0 PSI PSI 7 PSI PSI PSI PSI PSI* 8 PSI* PSI 7 PSI PSI PSI 77 PSI 0 PSI 0 PSI PSI PSI PSI 8 PSI PSI* PSI* PSI 8 PSI 9 PSI PSI 7 PSI PSI PSI PSI PSI PSI PSI 7 PSI PSI* PSI* 9 PSI* PSI PSI / ID BRAIDED Run Length Flow Rate (GPM) at 00 PSI INJECTOR Injector Color Black Black Black Black Nozzle Size 0. (.09 mm) 0.77 (.0 mm) 0.8 (.7 mm) 0.07 (. mm) 00 0 PSI PSI* PSI PSI 7 8 PSI PSI* PSI* PSI 0 PSI 8 PSI PSI* PSI* PSI PSI PSI 8 PSI ID BRAIDED Run Length Flow Rate (GPM) at 00 PSI INJECTOR Injector Color Black Black Black Black Nozzle Size 0. (.09 mm) 0.77 (.0 mm) 0.8 (.7 mm) 0.07 (. mm) 00 PSI PSI PSI 8 PSI 7 PSI PSI PSI PSI 0 PSI PSI PSI PSI PSI PSI PSI PSI Hydra-Flex, Inc. 08 Page

37 AQUA-LAB HD/XD - ACCESSORIES PART NAME PART NUMBER Duo-Foam Kit (HD/XD) 007 Triple-Foam Kit (HD/XD) 008 Distribution Manifold (HD/XD) 0089 High-Flow Rinse Kit (PC) 000 Anti-Siphon Kit (PC) 000 PC To PC Adapter (HD/XD) 0009 Injector Optimization Tool 0008 Vacuum Tester Kit 000 Water Filtration System - Cold 00 Water Filtration System - Cold Replacement Filter 0008 PC Plug - Stainless Steel Flow-Through Adapter Bug Prep Foam Generator For Prep Gun Replacement 0070 Bug Prep Foaming Prep Gun Replacement 007 Bug Prep Foaming Prep Gun,Hose, & Injector Replacement 007 Bug Prep Dual Lumen /8 Spiral Hoe 0 (9 m) 00 Aqua-Lab Rack Mounting Kit (Motor Control Unit Mounted Rack) Aqua-Lab Rack Mounting Kit (Variable Frequency Drive Mounted Rack) 00 Aqua-Lab Rack Mounting Kit (Rack Tray Option) Stainless Steel Motor Drip Shield (Wall Mounted Booster Pumps Only) 007 Kick Plate Cover (Floor Mounted Grundfos Pump Only) 009 Vinyl Hose Barb Cap 0007 Remote Metering Device/Check Hub 007 /8 Coupler 000 /8 Elbow 000 /8 x / Push-To-Connect 000 /8 Check Valve (PC) / Check Valve (PC) 0009 / to / Hose Barb & Check Valve Kit (PC) 008 / to Hose Barb & Check Valve Kit (PC) 008 Chemical OEM Parts Kit 008 Service Tech Parts Kit 008 Hydra-Flex, Inc. 08 Page 7

38 AQUA-LAB PANEL PARTS DIAGRAM / or 0 8 7/8 Hydra-Flex, Inc. 08 Page 8

39 NUMBER PART NAME PART NUMBER Air Actuated Hydra-Cannon Valve Replacement Kit - Stainless 0009 Single BAM Valve Replacement x / Push-To-Connect Air Fitting For Air Actuated Valve BAM Valve Repair Kit 00 Hydra-Cannon Valve O-Ring Repair Kit 00 BAM O-Ring Repair Kit 00 VAC Solenoid Actuated Air Valve - Foaming VDC VAC VAC Solenoid Coil Replacement For Air Actuated Valve VDC VAC M X Din I Cordset VAC/VDC VAC Primary Air Regulator 008 Primary Air Regulator Replacement Bowl 008 Foaming Small Air Regulator & 0 PSI Gauge 0087 Outlet Pressure Gauge 0-00 PSI Bottom Mount 0009 Inter Face Fitting Assembly 008 BAM Inlet Kit 009 Hydra-Cannon To BAM Coupler Hydra-Cannon End Plug Assembly BAM End Cap Kit (Not Shown) / Push To Connect Tee (Not Shown) / Push To Connect To /8 NPT Elbow (Not Shown) / Push To Connect To /8 NPT Elbow - Plastic 000 (Not Shown) / Hose Barb Foaming Air Check Valve M Junction Block - 8 Port, With Homerun Cable M Junction Block - Port, With Homerun Cable 0 (0 m) (0 m) (0 m) (0 m) Ball Valve Manifold Inlet ID Hose X NPT Ends - 7 (.8 m) Long Male Quick Connect - Brass Female Quick Connect - Brass Hydra-Flex, Inc. 08 Page 9

40 AQUA-LAB PUMP PARTS DIAGRAM or 7 7 NUMBER PART NAME PART NUMBER 7 Male Quick Connect - Brass Female Quick Connect - Brass Wye Strainer - 0 Mesh NPT T Wye Strainer Screen & Gasket Kit 0098 NPT T Wye Strainer Screen & Gasket Kit GPM (0 LPM) Bypass Pressure Regulator - Stainless Steel 000 Quick Connect 9 ( m) Cordset For Booster Pump Temperature Switch Assembly 00 0 GPM (7 LPM) Quick Connect Regulator Plumbing Assembly GPM (0 LPM) Grundfos Plumbing Assembly Grundfos Pump System Manifold O-Ring Replacement/Backup 0 GPM (0 LPM) Grundfos Pump Replacement/Backup 0 GPM (7 LPM) Booster Pump 00 0 (Not Shown) Booster Pump Floor Stand 000 Dual Booster Pump Wall Mount Bracket 0009 (Not Shown) Triple Booster Pump Wall Mount Bracket Hydra-Flex, Inc. 08 Page 0

41 AQUA-LAB CONTROL PARTS DIAGRAM or 9 0 or 8 or 9 7 NUMBER PART NAME PART NUMBER (Not Shown) M Cordset (Gray) 0007 High-Temp Light VAC/DC VAC Quick Connect Pump Plug - Female Thermal Overload - Eaton Timer Relay Current Sensor - AC Current Sensor - DC VFD Replacement - HP VFD Replacement - 7.HP 0V V V V (Not Shown) VFD MCU Keypad 007 VFD MCU Exhaust Fan 0089 VFD MCU Exhaust Filter 0088 VAC Contactor - Eaton VDC VAC (Not Shown) VFD MCU Pressure Transducer (Not Shown) Pressure Transducer Cable VFD MCU Primary Fuse / AMP VFD MCU Fuse 0A A VAC Smart Relay VDC VAC Hydra-Flex, Inc. 08 Page