AQUA-LAB SD GEN2 CHEMICAL DISPENSING SYSTEM. User Manual REV B revb0518

Transcription

1 AQUA-LAB SD GEN2 CHEMICAL DISPENSING SYSTEM User Manual REV B revb0518 Hydra-Flex, Hydra-Flex, Inc Inc Page 1

2 TABLE OF CONTENTS Specifications 3 Layout Drawing 4 Panel Diagram 5 Motor Control Unit (MCU) Diagram 6 Booster Pumps Diagram 7 Estimated Installation Timeline 8 Installation Instructions 8 MCU Wiring Diagram 11 Start Up - Booster Pumps 12 Appendix 14 Initial Injector Setup 14 Optimizing The System 15 Nozzle Setup 15 Recommended Maintenance 17 Air Operated SAM Valve Replacement 17 Troubleshooting 18 Injector Optimization Tool 20 Injector Vacuum Check 21 MCU High Temp Shutdown Restart Instructions 21 Chemical Dilution Ratios 22 PC1 Injector Part Numbers 23 Pressure Loss In Run Length 24 Replacement Parts 25 Replacement Panel Parts List & Digram - Aqua-Lab SD GEN2 25 Replacement Pump Parts List & Digram - Aqua-Lab SD GEN2 26 Replacement MCU Parts List & Digram - Aqua-Lab SD GEN2 27 Accessories - Aqua-Lab SD GEN2 27 Warranty 28 FOR ADDITIONAL SUPPORT CALL OR VISIT US ON THE WEB Hydra-Flex, Inc Page 2

3 SPECIFICATIONS 5 GPM (19 LPM) Booster Pump POWER REQUIREMENTS 10 GPM (38 LPM) Booster Pump Air-Actuated Valves 208V/220V/1PH/60Hz/6.4A* *Recommended for use with 15A breaker. 208V/220V/1PH/60Hz/9A* 24 VAC, 24 VDC, or 120VAC, 4 Watts/Port With Foaming Air 24 VAC, 24 VDC, or 120VAC, 0.5 Watts/Port Without Foaming Air SPACE REQUIREMENTS (DEPTH X WIDTH X HEIGHT) 1-Pump Wall-Mount Motor Control Unit (MCU) SD GEN2 Panels 9 x 17 x 45 (23 cm x 43 cm x 114 cm) 8 x 14 x 16 (20 cm x 36 cm x 41 cm) 8 x 38 x 19 (20 cm x 97 cm x 48 cm) WATER INLET LINES 5 GPM (19 LPM) Booster Pump 10 GPM (38LPM) Booster Pump 3/4 ID 3/4 ID SOLUTION OUTLET LINES Up to 2.25 GPM (8.5 LPM) GPM ( LPM) 3/8 ID (1/2 OD Polyflow*) 1/2 ID* *Assuming line length is 50 (15 m) or less. Refer to user manual for recommended size chart for other lengths. CHEMICAL DRAW TUBE 1/4 ID Clear Tube With Foot Valve Using 100 Mesh Screen OPERATING WATER PRESSURE 200 PSI (14 bar) Factory Set (Assumes 40 PSI (2.8 bar) City Feed) WATER SOURCE TEMP. MIN: 40 F (4 C), MAX: 137 F (58 C) WATER FILTRATION (SUGGESTED) 50 Micron AIR INLET LINE 3/8 OD Polyflow per Panel AIR OUTLET LINE 3/8 OD Polyflow per Application AIR INLET PRESSURE PSI ( bar) Dry Air INJECTOR SPECIFICATIONS Max Pressure Inlet/Outlet Temperature Range Max Wrench Torque Up to 250 PSI (17 bar) 40 F F (4 C - 60 C) Hand Tighten Only (30 in-lbs) Hydra-Flex, Inc Page 3

4 LAYOUT DRAWING (1x) 8 230V PUMP POWER CORD INCLUDED WITH EACH MCU (4x) TAPCON ANCHORS INCLUDED FOR EACH SD GEN 2 PANEL MCU BOX LOCATED WITHIN 6' OF PUMP MOTOR. AQUA-LAB SD GEN2 BOARD LOCATED WITHIN 6 OF MCU POWER FROM WALL SINGLE PHASE 208V OR 220V POWER IN PROVIDED BY OTHERS PRESSURE TRANSDUCER CABLE AQUA LAB SD GEN2 GEN 2 PANEL PRIMARY AIR REGULATOR 3/8" POLY FLOW AIR INLET TUBING PROVIDED BY OTHERS (120 PSI MAX) (4x) 3/8 CONCRETE ANCHORS INCLUDED WITH PUMP STAND OPTIONAL INLET SELCTOR AVAILBLE (2x).38 APPROXIMATELY /2" x 6' QUICK CHANGE FLEXIBLE HOSE WITH REGULATOR AND WYE-STRAINER TO AQUA LAB PUMP STAND LOCATED WITHIN 5' OF SD GEN2 BOARD ***Pump configuration will vary depending on specific order options. Hydra-Flex, Inc Page 4

5 PANEL DIAGRAM Water Pressure Gauge Foaming Air Valves 1-9 Water Valves 1-9 Inlet Selector Valve Quick Connect With Ball Valve Removable Service Panel Foaming Air Regulators 1-9 Primary Air Regulator Air Regulator drain FOR PART NUMBERS & DIAGRAMS VISIT Hydra-Flex, Inc Page 5

6 MOTOR CONTROL UNIT (MCU) DIAGRAM Smart Relay Disconnect Contactor Thermal Overload WATER VALVES 7-9 AIRVALVES 1-3 WATER VALVES 4-6 AIR VALVES 4-6 WATER VALVES 1-3 AIR VALVES HIGH TEMP CABLE 2. LOW AIR PRESSURE CABLE (OPTIONAL) 3. INLET SELECTOR VALVE CABLE HOME RUN CABLES TO PUMP POWERCORD FOR PART NUMBERS & DIAGRAMS VISIT POWER IN POWERCORD Hydra-Flex, Inc Page 6

7 5 GPM PUMP WITH INLET SELECTOR BOOSTER PUMPS DIAGRAM 5 GPM PUMP WITHOUT INLET SELECTOR Temperature Switch Inlet Selector Water Feed Connection(s) Wye-Strainer Bypass Regulator Pump Outlet (To Panel) 10 GPM PUMP WITH INLET SELECTOR 10 GPM PUMP WITHOUT INLET SELECTOR Temperature Switch Inlet Selector Water Feed Connection(s) Wye-Strainer FOR PART NUMBERS & DIAGRAMS VISIT Bypass Regulator Pump Outlet (To Panel) Hydra-Flex, Inc Page 7

8 ESTIMATED INSTALLATION TIMELINE PRE-INSTALLATION WHO TASK EST. TIME DISTRIBUTOR & CUSTOMER DETERMINE LOCATION TO INSTALL EQUIPMENT 1 HR PLUMBER INSTALL WATER SUPPLY LINE 4 HR ELECTRICIAN INSTALL ELECTRICAL SUPPLY LINE 4 HR TECHNICIAN LABEL ALL CONTROLLER RELAYS AT CONTROLLER 1 HR TECHNICIAN RUN SOLUTION AND AIR LINES (IF NECESSARY) 5 HR TECHNICIAN INSTALL AIR SUPPLY LINE 1 HR INSTALLATION TOTAL LABOR HOURS 16 HRS WHO TASK EST. TIME DISTRIBUTOR / TECHNICIAN HANG EQUIPMENT 1 HR TECHNICIAN CONNECT WATER, AIR AND SOLUTION LINES 1 HR TECHNICIAN CONNECT CONTROL LEADS TO MAIN CONTROLLER OR JUNCTION BOX 2 HR DISTRIBUTOR/TECHNICIAN STARTUP (INJECTOR, METERING TIP AND NOZZLE SELECTION) 3 HR DISTRIBUTOR/TECHNICIAN DOCUMENT CONFIGURATION 1 HR POST INSTALLATION TOTAL LABOR HOURS 8 HRS WHO TASK EST. TIME DISTRIBUTOR MONITOR & RECORD PERFORMANCE 2 HR / WK DISTRIBUTOR MAINTENANCE PER SCHEDULE OR AS NEEDED TOTAL HOURS SPENT TOTAL CUSTOMER TOTAL DISTRIBUTOR/TECHNICIAN TOTAL ELECTRICIAN 1 HR 15 HR 4 HR Installation takes approximately ONE day. An electrician and a plumber are needed for half a day. TOTAL PLUMBER 4 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 3/8 Concrete drill bit 5/32 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 Page 8

9 UNPACKING When unpacking your Aqua-Lab SD GEN2 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 45 from floor for easy injector access. ***See drawing in reference for general layout AQUA-LAB SD GEN2 (WALL MOUNT) 1. Drill (4) 5/32 holes on the wall wide on top, 22 wide on bottom and 15 tall. 2. Press Aqua-Lab SD GEN2 board tight against the wall. 3. Screw in 3/16 concrete screws with a washer. SYSTEMS WITH BOOSTER PUMPS & MCU PUMP ASSEMBLY - NEED TO BE WITHIN 6 OF FURTHEST AQUA-LAB SD GEN2 PANEL Note: Pump should be mounted as low as possible, this is especially important when tank fed. This will help pump maintain prime. 1. Remove pump bracket from pump mounting bracket. 2. Drill 3/8 holes in wall for pump mounting bracket (3 on center). 3. Hold pump mount bracket in place, insert anchors and tighten. 4. Connect pump to pump mounting bracket. MOTOR STARTER 1. Mount to the wall with 4 appropriate anchors. PNEUMATIC CONNECTIONS Connect pre-run 3/8 OD poly feed line to push connect fitting on the side of the primary regulator. Connect 3/8 OD poly lines from arch to each port that will be foaming. **If there are unused air ports, turn counter-clockwise the individual line regulator until air no longer flows. Hydra-Flex, Inc Page 9

10 ELECTRICAL CONNECTIONS (HFI MOTOR CONTROL UNIT) a. Wire homerun control cables to car wash control panel from the MCU. (See diagram on page 11 for wiring schematic) Below designates which valve port is associated to what color wire. GRAY HOME RUN CABLES WIRE COLOR WATER VALVE CABLE AIR VALVE CABLE Brown Constant Hot Inlet Selector Red OV/Neutral Not Used Green Ground Ground White Position 1 Foaming Air 1 Orange Position 2 Foaming Air 2 Yellow Position 3 Foaming Air 3 Gray Position 4 Foaming Air 4 Pink Position 5 Foaming Air 5 Tan Position 6 Foaming Air 6 Black Position 7 Foaming Air 7 Violet Position 8 Foaming Air 8 Blue Position 9 Foaming Air 9 1. Connect the home run cables - The SD GEN2 control box has two gray home run cables. The first is labeled Water valves, the second is labeled Air valves. The control box is designed such that the SAM water valves and foaming air valves can be actuated independently for cases where a common foaming valve would be used for several chemicals (i.e. several chemical are dispensed through the same applicator manifold). The gray home run cable labeled Water valves is used to actuate the SD water valves for chemical dispensing. When a water valve is actuated the booster pump is also started. The gray homerun cable labeled Air valves is used to actuate the foaming air valves only. When only an air valve is actuated without a water valve the booster pump is not started. 2. Connect the water and air valves The Aqua-Lab SD GEN2 panel valve cables will need to be connected to the control box. These cables are all labeled with their appropriate connection port. Depending on the number of ports and foaming air valves there may be up to 6 cable connections. Make sure to match the label on the cable to the label on the control box, otherwise the panel will not function as intended. Each connector is keyed such that orientation of the connector must be correct before the connector can be slid into it s receptacle in the control box. Once each connector is slid into place finger tighten the threaded nut to retain the connector (per diagram on page 6). 3. Connect the inlet selector The top right hand corner of the SD GEN2 panel has an air pressure valve used to control an optional inlet selector. This is connected to a pre-wired cable from the control box, simply slide the connector over the exposed prongs and gently tighten the retaining screw with a flat head screw driver. A 1/4 air line is provided with the inlet selector ball valve. This airline should be connected to the furthest right hand air valve as indicated on page Connect the pump power a. (See next page) b. (See next page) c. (See high temp switch next page) Hydra-Flex, Inc Page 10

11 2L1 N GND GND BRANCH CIRCUIT PROTECTION TO BE PROVIDED BY INSTALLER 240V 1PH: MAX FUSE CLASS CC 15A MAX BREAKER 25A (inverse-time) 240V 3PH: MAX FUSE CLASS CC 10A MAX BREAKER 15A (inverse-time) DSC01 NOTE: L3 AND 1T3 NOT USED FOR 1PH MCU WIRING DIAGRAM 240V 1 PHASE PHASE 60 HZ L1 L2 L3 GND 1L3 14AWG/4 COND (12') 14AWG, BLK 1L1 1L2 1L1 1L2 1L3 MS01 OL01 1T1 1T2 1T3 1T1 1T2 1T3 14AWG/4 COND (12') FLA: M1 1.5HP 10(240V 1PH) 6(240V 3PH) OVERLOAD NOTES: 1) SET THERMAL OVERLOAD DIP SWITCH LEFT TO RIGHT: UP, DWN, DWN, UP 2) SET THERMAL OVERLOAD AMPS TO 12 AMPS BRN, WATER CBL. RED, WATER CBL. 2L1 N 18AWG, ORG 18AWG, WHT PLC01 EATON EASY RELAY EASY512-AB-RCX N 2L1 V1 V2 BRN WHT, AIR CBL. WHT J4-1 J4-2 AIR 1 AIR 2 (f) (f) J4-3 GRN, WATER CBL. GRN, AIR CBL. WATER 1 "ON" WATER 2 "ON" WATER 3 "ON" WATER 4 "ON" BLU BLU 3 RESET PB1 TEMP SWITCH TMP01 1 J1-3 J2-3 J1-1 J1-2 J1-4 J BRN WHT, WATER CBL. WHT ORG, WATER CBL. BLK YEL, WATER CBL. BRN L N N I1 I2 I3 I4 I5 I6 I7 I8 Q1 Q1 Q2 Q2 Q3 Q3 Q4 Q4 2L L1 202 MS01 A1 A2 RESET LIGHT GREEN X1 X2 OL95 OL V3 V4 V5 V6 V7 V8 V9 V10 ORG, AIR CBL. BLK YEL, AIR CBL. BRN GRY, AIR CBL. WHT PNK, AIR CBL. BLK TAN, AIR CBL. BRN BLK, AIR CBL. WHT VIO, AIR CBL. BLK BLU, AIR CBL. J4-4 J5-1 J5-2 J5-4 J6-1 J6-2 J6-4 AIR 3 AIR 4 AIR 5 AIR 6 AIR 7 AIR 8 AIR 9 AIR 10 (f) (f) (f) (f) (f) (f) (f) (f) J5-3 J6-3 GRY, WATER CBL. BRN, AIR CBL. J WHT WATER 5 "ON" GRAY HOME RUN CABLES PNK, WATER CBL. J BLK WATER 6 "ON" TAN, WATER CBL. J3-3 J BLU BRN WATER 7 "ON" BLK, WATER CBL. J WHT WATER 8 "ON" VIO, WATER CBL. WATER 9 "ON" 2L1 N J3-4 BLK BLU, WATER CBL NOTES: 1) MOTOR AND CONTROL CIRCUITS ARE TWO SEPERATE POWER SUPPLIES 2) ALL WIRES ARE ORANGE 18 AWG MTW UNLESS OTHERWISE NOTED 3) ALL CONTROL CIRCUIT NEUTRALS WIRES ARE WHITE 18 AWG MTW 104 OPTIONAL PRESSURE SENSOR PRS INSTALL JUMPER FROM 104 TO 2L1 ( REMOVE IF PRS01 IS INSTALLED) N 2L1 (f) = FIELD TESTED = FIELD WIRED BLU BLU BLU N N N N Hydra-Flex, Inc Page 11

12 FEED WATER CONNECTION HFI BOOSTER PUMP SECTION **PRIOR TO CONNECTION, ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES Connect pre-run main water supply line to pump inlet with hose supplied. Single pump without inlet selector: (1x) 3/4 MNPT Single pump with inlet selector: (2x) 3/4 MNPT START UP - BOOSTER PUMPS!WARNING! PUMP MUST BE PRIMED BEFORE OPERATION 1. 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. 1 min). Then close the ball valve. a. Wire the incoming power cord to single phase 208/240V electrical power. Only green, white, & black wires are used. Red is not used (see page 11 for details). b. Wire the pump power cord to the pump. Only green, black, & white wires are used. Red is not used (see page 11 for details). Make sure to follow all applicable electrical codes. c. Quick connect high temp shutdown switch. Connect the high temp switch from the pump assembly to MCU (Image 1). 2. PURGE BYPASS Start the pump and slowly open ball valve until it is wide open. Allow to run for 60 seconds to flush lines and then close valve. 3. CONNECT Connect the pump outlet line to the manifold and open ball valve. (Image 1) Hydra-Flex, Inc Page 12

13 HFI BOOSTER HFI BOOSTER PUMP PUMP SECTION 4. DOUBLE CHECK Confirm that the pump can obtain 200 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 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 2). Verify pump prime 24 hours after operation to ensure prime held. Pay close attention to the temperature of the whole stainless steel area (Image 3). If it starts getting hotter than the supply water or greater than 137, 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 3) (Image 2) NOTE: A solid red light indicates an overheat situation (Image 4). This can be reset by following the instructions on the MCU (motor control unit). When the optional air pressure switch is installed a blinking red light indicates a low air pressure warning. A low air pressure warning will not shutdown the pump, but it indicates a condition that can lead to an overheat condition. Check to make sure that air pressure remains above 80 PSI at all times. (Image 4) Hydra-Flex, Inc Page 13

14 APPENDIX INITIAL INJECTOR SETUP (Based on field experience this is HFI s recommended starting point) 1. Using the target flow rate and the chemical dilutions chart (appendix Page 22) install the appropriate injector into each port. 2. 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 coupler and push connect fitting to ensure there are no leaks. b. Do not over tighten poly fittings or they may crack (HAND TIGHTEN ONLY). 3. 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 (100 mesh screen recommended). i. These must be present or metering tips may clog. 4. Metering tips will need to be installed to set dilution ratio (see appendix Page 22 for ratio charts to determine tip.) Hydra-Flex, Inc Page 14

15 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 21 for Injector Vacuum Check Instructions or page 18 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 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 Page 15

16 INJECTOR FLOW 200 PSI (GPM) INJECTOR FLOW 200 PSI (GPM) MINIMUM NUMBER OF NOZZLES NECESSARY WITHOUT FOAMING AIR (Assuming <10 PSI line loss and ~ 40 PSI at the nozzle) SPRAY NOZZLE SIZE # 2.0 # 3.0 # 4.0 # 5.0 # 6.0 # 7.0 # 8.0 # 9.0 # 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 # 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 1. Set up lab scale with small bucket of chemical to be measured. 2. Put the suction line into the bucket. 3. Run the application being tested to prime the line. (All air bubbles must be removed for accuracy.) 4. Record the Initial Weight from the scale. (Taring the scale with weight on the scale can affect accuracy.) 5. Run the application for 1 vehicle (or manually for the same amount of time it would be on for 1 vehicle). 6. 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 Page 16

17 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 1 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. 1-3 Years Inspect and replace injectors. Replace water valves. Replace main pressure regulator. AIR OPERATED SAM VALVE REPLACEMENT C B A 2 1 ENSURE SYSTEM WATER SUPPLY IS OFF AND POWER TO SOLENOIDS ARE IN A LOCK OUT / TAG OUT MODE BEFORE STARTING. 1. Loosen and remove end cap (A) using a adjustable wrench (use caution, cap is spring loaded). 2. Push out spring (B) and Piston (C) through injector socket (1). 3. Make sure all o-rings are lubricated with silicone grease before inserting. 4. Insert new piston (C) into valve housing (2). Push down with your finger until it is seated. 5. Insert spring (B) into valve housing (2). 6. Thread end cap (A) back into valve housing. Use adjustable wrench to snug tight (DO NOT OVER TIGHTEN). Hydra-Flex, Inc Page 17

18 PUMP ISSUES TROUBLESHOOTING PROBLEM POTENTIAL CAUSES SOLUTIONS Pump Operates, But Delivers Little Or No Water Overheat Light On Pump Will Not Start Or Run At Full Speed Overheat Light Blinking Pump not primed 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 Pump components damaged Low Air Pressure See priming instructions. 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 110 F Max, injector flow to 10 GPM max. Increase continuous flow to at least 3/4 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 10% of motor rated voltage. (Check that pump is wired for correct voltage.) Replace motor. Replace worn part or entire pump. Low shop air pressure < 80 PSI likely to have caused temperature trip. Increase air pressure 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 60 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 Page 18

19 PRESSURE REGULATOR ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS System Won t Regulate Up To 200 Psi Pump not primed Debris in regulator 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 Follow priming instructions. Remove regulator and clean out debris. 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. FLOW / ARCH ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Flow At Arch Is Too Low VALVE ISSUES 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 200psi Ensure cleaned and clear PROBLEM POTENTIAL CAUSES SOLUTIONS 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 230 psi Air exhaust muffler is clogged Ensure primary air regulator reading at least 60 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 018 & 008 Viton O-ring and lubricate with Dow 111 valve lube. Reduce pressure to manifold to 200 psi operating pressure. Replace exhaust muffler. Hydra-Flex, Inc Page 19

20 INJECTOR OPTIMIZATION TOOL BACKGROUND: This tool is for initial setup and troubleshooting of Chem-Flex Injectors and an Aqua-Lab SD GEN2 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: 1. Plug the optimization tool into the outlet line of injector and connect solution output line. 2. Turn on function from car wash controller to actuate valve such that fluid is flowing through both the injector and injector optimization tool and out to the applicator. 3. Read injector optimization tool. 4. 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. 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) 1. Foam generators are clogged/degraded. Clean or replace media in generator. 2. Injector flow size is too large. Go down an injector size (less GPM). 3. Nozzle size on the arch is too small. Go up in nozzle size. 4. Check valves are dirty and or failing. Clean or replace check valves. 5. 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. 6. 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) 1. Injector flow too low. Increase injector size. 2. Nozzle size too large. Reduce nozzle size. Hydra-Flex, Inc Page 20

21 INJECTOR VACUUM CHECK (FOR TROUBLESHOOTING INJECTORS) 1. At the Chem-Flex injector, remove the chemical feed line from the injector hose barb. 2. Attach the tubing of the vacuum gauge to the Chem-Flex hose barb (Image A). 3. 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 ( ) 20 in Hg. 4. If vacuum reads <20 in/hg (image B), remove solution metering tip (image C) and retest. 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. Remove a nozzle on the arch or the chemical feed line from the foam generator and retest vacuum. 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. D 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. Repeat steps 2-5 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 2. 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). 2. Point hose to drain and open ball valve to purge hot water and cool pump for several minutes (USE CAUTION). 3. When pump is sufficiently cooled close ball valve, reconnect hose, open ball valve and press red button on MCU to restart. 4. Determine why system overheated. See troubleshooting section (page 18 Overheat Light On). 3. Hydra-Flex, Inc Page 21

22 CHEM-FLEX INJECTORS - 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 200 PSI (14 bar)) #8-32 Metering Tips Flow Rate (GPM) at 200 PSI Injector Color Yellow Tan Red Orange Gray Blue Light Blue Light Green Pink COPPER 1: 104 1: 155 1: 195 1: 281 1: 406 1: 468 1: 598 1: 629 1: 739 PUMPKIN 1: 82 1: 119 1: 126 1: 238 1: 348 1: 398 1: 519 1: 554 1: 647 BURGUNDY 1: 67 1: 97 1: 111 1: 207 1: 304 1: 347 1: 461 1: 495 1: 575 LIME 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 414 1: 447 1: 518 TAN 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 414 1: 447 1: 518 ORANGE 1: 44 1: 64 1: 78 1: 137 1: 196 1: 215 1: 293 1: 314 1: 365 TURQUOISE 1: 31 1: 45 1: 55 1: 91 1: 126 1: 134 1: 185 1: 197 1: 230 PINK 1: 24 1: 35 1: 42 1: 68 1: 93 1: 98 1: 130 1: 143 1: 159 Metering Tip LIGHT BLUE 1: 17 1: 24 1: 31 1: 47 1: 64 1: 66 1: 93 1: 98 1: 114 BROWN 1: 15 1: 22 1: 28 1: 43 1: 58 1: 59 1: 84 1: 88 1: 103 RED 1: 12 1: 17 1: 23 1: 34 1: 45 1: 46 1: 65 1: 69 1: 80 WHITE 1: 12 1: 16 1: 22 1: 31 1: 42 1: 43 1: 61 1: 64 1: 74 GREEN 1: 11 1: 14 1: 20 1: 28 1: 37 1: 38 1: 53 1: 55 1: 65 BLUE 1: 10 1: 12 1: 17 1: 23 1: 30 1: 31 1: 44 1: 46 1: 53 YELLOW 1: 9 1: 12 1: 16 1: 20 1: 22 1: 30 1: 31 1: 36 BLACK 1: 10 1: 13 1: 16 1: 17 1: 23 1: 24 1: 28 PURPLE 1: 6.6 1: 8.3 1: 9 1: 10 1: 13 1: 13 1: 15 GRAY 1: 5.3 1: 6.7 1: 6.9 1: 7.6 1: 9.9 1: 10 1: 11.6 OPEN 1: 4.9 1: 5.3 1: 5.2 1: 6.0 1: 6.1 1: 6.1 1: : 503 1: 754 1: : : : : : : 2628 Spiral Plug Length : 363 1: 544 1: 726 1: : : : : : : 208 1: 311 1: 415 1: 623 1: 831 1: 934 1: 835 1: 778 1: : 165 1: 247 1: 329 1: 494 1: 659 1: 741 1: 642 1: 668 1: : 119 1: 178 1: 238 1: 357 1: 475 1: 535 1: 487 1: 496 1: : 68 1: 102 1: 136 1: 204 1: 272 1: 306 1: 282 1: 304 1: 344 3/8 polyflow (LLDPE) tubing is required to ensure a seal between the tube wall and the spiral plug. Hydra-Flex, Inc Page 22

23 PC1 INJECTOR PART NUMBERS INLET CONNECTION OUTLET CONNECTION FOR USE WITH AQUA-LAB MODEL(S) PC1 1/4 MNPT SD GEN2 COLOR FLOW 200 PSI (13.9 bar) SINGLE BARB DUAL BARB Yellow 0.50 GPM (1.9 LPM) Tan 0.75 GPM (2.8 LPM) Red 1.00 GPM (3.8 LPM) Orange 1.50 GPM (5.7 LPM) Gray 2.00 GPM (7.6 LPM) Dark Blue 2.25 GPM (8.5 LPM) Light Blue 3.00 GPM (11.3 LPM) Light Green 3.25 GPM (12.3 LPM) Pink 3.75 GPM (14.2 LPM) PC1 INJECTOR SPECIFICATIONS Max Pressure Inlet/Outlet Temperature Range Max Wrench Torque Up to 250 PSI (17 bar) 40 F F (4 C - 60 C) Hand Tighten Only (30 in-lbs) Hydra-Flex, Inc Page 23

24 PRESSURE LOSS IN RUN LENGTH GREEN = GOOD YELLOW= USE CAUTION RED = NOT RECOMMENDED 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. 5/8 ID BRAIDED Run Length Flow Rate (GPM) at 200 PSI INJECTOR Injector Color Yellow Tan Red Orange Gray Nozzle Size (1.0 mm) (1.3 mm) (1.4 mm) (1.8 mm) (2.1 mm) Dark Blue (2.2 mm) Light Blue (2.41 mm) Light Green (2.5 mm) Pink (2.69 mm) PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 6 PSI 7 PSI 9 PSI PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 8 PSI PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 75 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 3 PSI 4 PSI 5 PSI 50 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 3 PSI 25 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 1/2 ID BRAIDED Run Length Flow Rate (GPM) at 200 PSI INJECTOR Injector Color Yellow Tan Red Orange Gray Blue Nozzle Size (1.0 mm) (1.3 mm) (1.4 mm) (1.8 mm) (2.1 mm) (2.2 mm) Light Blue (2.41 mm) Light Green (2.5 mm) Pink (2.69 mm) PSI 2 PSI 3 PSI 6 PSI 9 PSI 11 PSI* 18 PSI* 21 PSI 27 PSI PSI 2 PSI 3 PSI 5 PSI 8 PSI 9 PSI 15 PSI* 18 PSI* 23 PSI PSI 2 PSI 2 PSI 4 PSI 7 PSI 8 PSI 12 PSI* 14 PSI* 18 PSI* 75 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 6 PSI 9 PSI 11 PSI* 14 PSI* 50 1 PSI 1 PSI 1 PSI 2 PSI 4 PSI 4 PSI 6 PSI 8 PSI 9 PSI 25 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI 5 PSI 3/8 ID, 1/2 OD POLY TUBE Run Length Flow Rate (GPM) at 200 PSI INJECTOR Injector Color Yellow Tan Red Orange Gray Blue Nozzle Size (1.0 mm) (1.3 mm) (1.4 mm) (1.8 mm) (2.1 mm) (2.2 mm) Light Blue (2.41 mm) Light Green (2.5 mm) Pink (2.69 mm) PSI 7 PSI 11 PSI* 22 PSI 36 PSI 44 PSI 76 PSI 88 PSI 115 PSI PSI 6 PSI 9 PSI 18 PSI* 30 PSI 37 PSI 63 PSI 73 PSI 101 PSI PSI 5 PSI 7 PSI 14 PSI* 23 PSI 28 PSI 50 PSI 54 PSI 77 PSI 75 2 PSI 4 PSI 6 PSI 12 PSI* 18 PSI* 22 PSI 37 PSI 42 PSI 53 PSI 50 1 PSI 3 PSI 4 PSI 8 PSI 12 PSI* 15 PSI* 25 PSI 28 PSI 39 PSI 25 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 7 PSI 12 PSI* 13 PSI* 19 PSI* Hydra-Flex, Inc Page 24

25 REPLACEMENT PANEL PARTS LIST & DIGRAM - AQUA-LAB SD GEN NUMBER PART NAME PART NUMBER 24VAC Port SAM Valve Replacement 24VDC VAC SAM Valve Repair Kit SAM O-Ring Repair Kit SAM Manifold Repair Kit SAM Wire (Air Valves) SAM Wire (Manifold) Foaming Small Air Regulator & 60 PSI Gauge Zip Tie Outlet Pressure Gauge PSI Bottom Mount VAC Solenoid Actuated Air Valve - Foaming 24VDC VAC VAC (Not Shown) Solenoid Actuated Air Valve Replacement Kit 24VDC VAC Primary Air Regulator (SD GEN2) VAC Solenoid Coil Replacement For Air Actuated Valve 24VDC VAC VAC SAM Pilot Valve 24VDC VAC Primary Air Regulator Replacement Bowl (SD GEN2) SAM End Cap Kit SAM Inlet Kit Hydra-Flex, Inc Page 25

26 REPLACEMENT PUMP PARTS LIST & DIGRAM - AQUA-LAB SD GEN or or NUMBER PART NAME PART NUMBER 18 (Not Shown) Manifold Inlet 3/4 ID Hose X 1/2 NPT Ends - 72 (1.8 m) Long (Not Shown) 1/2 Ball Valve (Not Shown) 1/2 Male Quick Connect - Brass (Not Shown) 1/2 Female Quick Connect - Brass /4 Wye Strainer - 20 Mesh /4 NPT T16 Wye Strainer Screen & Gasket Kit /4 NPT T15 Wye Strainer Screen & Gasket Kit /4 Pressure Relief Valve Temperature Switch Assembly GPM (19 LPM) Pump Replacement GPM (38 LPM) Pump Replacement Or 10 GPM (19 or 38 LPM) Pump Plumbing Assembly With Inlet Selector Or 10 GPM (19 or 38 LPM) Pump Plumbing Assembly Inlet Selector Hydra-Flex, Inc Page 26

27 REPLACEMENT MCU PARTS LIST & DIGRAM - AQUA-LAB SD GEN NUMBER PART NAME PART NUMBER 32 High-Temp Light 24VAC/DC VAC Thermal Overload - Eaton VAC Smart Relay 24VDC VAC VAC Contactor - Eaton 24VDC VAC MCU Disconnect Switch & Handle Replacement Kit SD GEN ACCESSORIES - AQUA-LAB SD GEN2 PART NAME PART NUMBER Anti-Siphon Kit Injector Optimization Tool Vacuum Tester Kit Water Filtration System - Cold Replacement Filter Cartridge Vinyl Hose Barb Cap Remote Metering Device/Check Hub /8 Elbow /8 x 1/2 Push-To-Connect /4 To 3/8 Check Valve Hydra-Flex, Inc Page 27

28 AQUA-LAB WARRANTY FACTORY LIMITED Hydra-Flex, Inc warrants its equipment to be free from defect in material or workmanship under proper normal use for a period of one (1) year beginning the date of purchase. Hydra-Flex, Inc s liability shall be limited to repair or replacement of parts found to be defective within the warranty period and following Hydra-Flex, Inc s inspection. Hydra-Flex, Inc shall have the option requiring the return of defective material to establish the purchaser s claim. In the event of repair or replacement this limited warranty is non-cumulative. Neither labor nor transportation charges are included in this warranty. This warranty is based upon the proper care and maintenance of the warranted equipment. Warranty does not apply if the merchandise is altered or modified in any way. Warranty does not apply to any equipment which has been subject to misuse, inappropriate use of tools, including exposure to harsh chemicals, neglect, lack of maintenance, freezing, fluid hammer, accident, third party damage, fluid impurities such as sand or minerals, acts of God or acts of war. Nor does it apply to any equipment which has been repaired or altered by anyone not so authorized by Hydra-Flex, Inc. All equipment must be properly installed in accordance with specified plumbing, electrical, and mechanical requirements. The warranty does not apply to normal wear and tear or routine maintenance components as described in the equipment manual. Except as expressly stated herein, Hydra-Flex, Inc shall not be liable for damages of any kind in connection with the purchase, maintenance, or use of this equipment including loss of profits and all claims for consequential damages. This limited warranty is in lieu of all other warranties expressed or implied. Hydra-Flex, Inc neither assumes nor authorizes any person to assume for it any other obligation or liability in connection herewith. This warranty is neither assignable nor transferable. Transportation damage claims are to be submitted to the carrier of the damaged material. T: sales@hydraflexinc.com Hydra-Flex, Inc revb0518 Page 28