BUG PREP KIT 2.0 HAND-PREP SYSTEM User Manual REV A 4000110 reva0616 Hydra-Flex, Hydra-Flex, Inc. 2016 Inc. 2016 Page 1
TABLE OF CONTENTS Overview 3 Standard Bug Prep Kit 2.0 3 Bug Prep Retro Controller (Retro Only) 3 Bug Prep Kit 2.0 Retro Installation Steps 4 Bug Prep 2.0 Installation Steps 6 Standard Operating Procedure 7 How To Reduce Temp If Temp Overload Box is Tripped 7 Trouble Shooting 7 Preventative Maintenance 7 Bug Prep Kit 2.0 Warranty 8 FOR ADDITIONAL SUPPORT CALL 952-808-3640 OR VISIT US ON THE WEB: www.hydraflexinc.com Hydra-Flex, Inc. 2016 Page 2
OVERVIEW The Aqua-Lab Bug Prep Kit 2.0 integrates injector-based chemical dispensing with a pressure switch actuated foaming prep gun and a high temperature shutdown system to protect your pumps. The injector plugs into a Hydra-Cannon position and turns on the pump to create boosted chemical solution when a hand actuated gun is squeezed. If a failure occurs somewhere in the system causing the pump to run and bypass water the temperature switch detects the temperature increase and shuts down the pump. If the pump is shut down due to a temperature trip a red light will become illuminated. STANDARD BUG PREP KIT 2.0 Outlet Solution Line Pressure Switch Box Din I Plug M12 Connector Injector Assembly BUG PREP RETRO CONTROLLER (RETRO ONLY) 3 Pin Electrical Quick Connect (Retrofit Prep Only) 120V Wall Outlet Plug In Temperature Overload Reset Button 2 Pin Electrical Quick Connect 3 Pin Electrical Quick Connect Hydra-Flex, Inc. 2016 Page 3
BUG PREP KIT 2.0 RETRO INSTALLATION STEPS 1. Mount bug prep pressure switch box within 3 of Aqua-Lab panel M12 junction block. 2. Mount temperature overload box next to panel within 32 of the bug prep pressure switch box and within 14 of the pump that plumbs into the corresponding Aqua-Lab panel the bug prep. 3. Shutoff water to pump inlet, turn off power to pump (not shown). 4. Close ball valve at the Hydra-Cannon inlet. 5. Disconnect quick connect on feed line to panel (not shown). 6. Aim hose at drain. Open ball valve and run till water stops coming out of hose. 7. Plumb temperature switch into bypass line (see photos below). 8. Connect injector to manifold. Route 1/2 poly flow to top port on pressure switch box. Step 6 Step 7 Step 7 Cut Bypass line close to the end of hose bar, loosen hose clamp Plumb in temp switch to regulator, connect hose to hose barb and re-tighten hose clamp 9. Plumb outlet solution line (3/8 poly flow from side port of pressure switch box) and airline to bay (not included). 10. Connect solution and airline to dual lumen hose. 11. Connect dual lumen hose to wye connector on foaming gun (Red Line is used for air, Blue Line is used for chemical solution). 12. Attach M12 connector on injector manifold to corresponding Aqua-Lab junction block port. 13. Connect Din I to corresponding Aqua-Lab electric actuated air valve. 14. Connect 3 pin electrical quick connect on injector manifold to 3 pin electrical quick connect on temperature shutdown box. Connect 2 pin electrical quick connect on temperature switch to 2 pin electrical quick connect on temperature shutdown box. a. Turn on water supply to pump (not shown). b. When water is coming out of feed line for 30 seconds close ball valve, re-prime pump (not shown). c. Reconnect feed line to panel (not shown). d. Press red light on temperature overload box. 15. Open ball valve on feed line, pump and valve will activate until 100 psi is stored in line. Once pressure is made between the gun and valve, the pump will turn off after approximately 20 seconds (not shown). 16. Verify that the system is leak free (not shown). 17. Verify that the pump turns on when the gun trigger is squeezed (not shown). 18. Verify the pump turns off when the gun in closed (not squeezed). Pump should turn off after approximately 20 seconds of releasing the gun (not shown). Hydra-Flex, Inc. 2016 Page 4
Step 2 Step 15d Step 13 Step 12 Step 14 Step 8 Step 4 Step 1 Step 9 Step 15 Step 10 Step 11 Hydra-Flex, Inc. 2016 Page 5
BUG PREP KIT 2.0 INSTALLATION STEPS 1. Mount bug prep pressure switch box within 3 of Aqua-Lab panel M12 junction block. 2. Close ball valve at the Hydra-Cannon inlet, turn off power to pump. 3. Connect injector to manifold, route ½ poly flow tubing to top port on pressure switch box. 4. Plumb outlet solution line (3/8 poly flow from side port of pressure switch box) and airline to bay (not included). 5. Connect solution line and airline to dual lumen hose. 6. Connect dual lumen hose to wye connector on foaming gun (red line is used for air, blue line is used for chemical solution). 7. Attach M12 connector on injector manifold to corresponding Aqua-Lab junction block port. 8. Connect Din I to corresponding Aqua- Lab electric actuated air valve. Step 2 Step 1 9. Once all plumbing and electrical connections are made, turn on power to the pump and slowly open the ball valve at the inlet of the Hydra-Cannon manifold. The pump will remain on until 100 PSI is stored in the solution outlet line. (This should take approximately 20 seconds.) 10. Verify that the system is leak free. Step 6 Step 4 11. Verify that the pump turns on when the gun trigger is squeezed. Step 8 Step 7 Step 3 Step 5 12. Verify the pump turns off when the gun in closed (not squeezed). Pump should turn off after approximately 20 seconds of releasing the gun. Hydra-Flex, Inc. 2016 Page 6
hydraflexinc.com STANDARD OPERATING PROCEDURE 1. Squeeze hand applicator trigger. a. Pump will turn on and valve will open simultaneously. 2. Apply solution to vehicle. 3. Release hand applicator trigger. a. Pump will build pressure in the bug prep solution line to 100 PSI and pump will shut down approx. 20 seconds later. HFI STRONGLY RECOMMENDS SHUTTING DOWN YOUR SYSTEM AT NIGHT TO PREVENT ANY UNINTENDED OPERATION HOW TO REDUCE TEMPERATURE IF TEMPERATURE OVERLOAD BOX IS TRIPPED 1. Close ball valve at inlet to Hydra-Cannon manifold. 2. Press red button on electric actuated air valve to purge pressure. a. Press and hold red button to purge pressure. Disconnect ball valve from Hydra-Cannon Inlet once pressure gauge reads 0 PSI. 3. Point valve towards drain, and slowly open to flush water through pump. Flushing water through pump will cool down the thermal switch. Once the thermal switch is cooled, press the illuminated red light on temperature overload box and reconnect ball valve to the panel. 4. Open ball valve. TROUBLE SHOOTING PROBLEM POTENTIAL CAUSES SOLUTIONS Injector Does Not Draw Chemical Pump Does Not Turn On Pump Will Not Turn Off 1. Back pressure is too high. 2. Metering tip clogged. 3. Foot valve is clogged. 1. Temperature overload is not plugged in. 2. Light on temperature overload box is illuminated. 3. Temperature overload is tripped. 1. Leak in line 2. Pressure switch failed PUMP 1 AQUA-LAB MD5 Chemical Dispensing System 1. Reduce foaming air pressure. 2. Increase nozzle size. 3. Increase solution outlet line size. 4. Clean/replace foam generators. 5. Clean metering tip. 6. Clean foot valve. 1. Plug temperature overload box in. 2. Press temperature overload reset button. 3. Reduce pump temperature by purging pump system with cold water, hit reset button once pump has been purged with cold water. 1. Fix leaks 2. Replace injector manifold 3. Replace check valve on airline Air Valve Chatters 1. Back pressure is too high 1. Decrease back pressure to below 60 PSI PREVENTATIVE MAINTENANCE TIME FRAME Daily Weekly Monthly ACTION Check for standard operating function: When the gun handle is squeezed, the pump turns on. When the gun handle is released, the pump turns off. Check for leaks that may cause the pressure switch to trigger. Inspect check valves on airlines to make sure valves are working. Replace when needed. Hydra-Flex, Inc. 2016 Page 7
BUG PREP KIT 2.0 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. 952-808-3640 www.hydraflexinc.com sales@hydraflexinc.com Hydra-Flex, Inc. 2016 4000110 reva0616 Page 8