AQUA-LAB AX, BX, TX CHEMICAL DISPENSING SYSTEM User Manual REV A 4000133 reva0717 Hydra-Flex, Hydra-Flex, Inc. 2017 Inc. 2017
TABLE OF CONTENTS Overview 1 Features 1 Specifications 1 Installation Instructions 2 Installation Specifications 2 Unpacking 2 Location and Mounting 3 Feed Water Connection 4 Chemical Line Connections 4 Pneumatic Connections 4 Electrical Connections 5 Operation 6 Pump Priming Instructions 6 Water Flow Rate and Chemical Dilution Set Up 6 Post Installation Vacuum & Back Pressure Check 7 Chem-Flex Injector Vacuum Check 7 Chem-Flex Back Pressure Check 7 Individual Injector Flow Rate Measurement 8 Troubleshooting 8 Appendix 10 Chemical Metering & Dilution Charts 10 Terminal Box Wiring Instructions (Optional) 11 Replacement Panel, Pump, & MCU Parts List 12 FOR ADDITIONAL SUPPORT CALL 952-808-3640 OR VISIT US ON THE WEB: www.hydraflexinc.com Hydra-Flex, Inc. 2017
FEATURES OVERVIEW Consistent and accurate chemical application Flexible pump design flow rates FROM 10 to 40 GPM Compact design reduces footprint Pre-wired and pre-plumbed for fast installation Easy Plug-and-Play utility and chemical connections Modular design customized to your needs for up to 15 chemicals plus Tri-Foam Uses Hydra-Cannon Chemical Manifold Systems for easy and quick service Color-coded Chem-Flex Injectors using Quick-Change connections For new installations or retrofit in any car wash The AQUA-LAB will simplify the delivery of liquid chemicals to your car wash arch. Its plug-and play system is compact and pre-assembled for quick installation. To ensure that the AQUA-LAB will interface properly with your car wash facility, you must first verify that your facility has all of the proper space and connection requirements according to the specifications below. You must also verify that you have ordered the proper part number for your AQUA-LAB to match the requirements needed by your facility. SPECIFICATIONS UP to 15 Chemical Ports Up to 15 Pneumatic Ports Hydraulics operating pressure: 200 psi (Factory set) Pneumatics operating pressure: 100 psi (Factory set) Operating Ambient Temperature: 40-120 Deg F Operate pumps with 208/230 or 480 Voltages (3-phase) Operate Solenoid Valves with 24VAC, 24VDC, 120VAC 1-1/2 water supply line (TX Model) 1 water supply line (AX & BX Models) Inlet pressure: 2-80 psi Space Requirements: a. Aqua Lab Systems i. TXF Model 3 x 3 footprint with 5 Clearance ii. TXW Model 2 wide x 4.5 high of wall space for system iii. AX Model 3 wide x 2 high of wall space for system iv. BX Model 1.5 wide x 2 high of wall space for system b. Pump Assemblies Pumps need to be within 3 of the system to allow connection of the two with just the included connection hose i. Single Pump 4 x 1 wall space ii. Dual Pump Wall mount 4 x 3 of wall space iii. Dual Pump Floor skid 4 wide x 1.5 deep footprint with 4 of Clearance c. Electrical Enclosures i. Motor Starter (AX and BX Models) 1 wide x 1.5 high of wall space ii. VFD Motor Controller 1.5 wide x 2 high of wall space iii. Terminal Box (Accessory) 1 wide x 1 high of wall space Hydra-Flex, Inc. 2017 Page 1
INSTALLATION INSTRUCTIONS INSTALLATION SPECIFICATIONS The AQUA-LAB chemical delivery system has been designed for a fast and hassle free installation. It comes fully assembled with all of the components pre-wired and plumbed, leaving only the setting of equipment, and connection of the incoming and outgoing hoses and wires. As follows are the installation specifications for the AQUA-LAB: GENERAL: People Required: 2 people Mechanical Skill Level: Basic - Mounting equipment Electrical Skill Level: Advanced - Three phase power and knowledge of local codes is required Pneumatic Skill Level: Basic- pneumatic utility connection required Fluid Skill Level: Basic - Water utility connection required Chemical Knowledge: Advanced - Chemical titrations required TOOLS AND EQUIPMENT NEEDED: Unpacking: Normal hand tools Assembly: Normal hand tools Wiring: Normal electrical wiring tools Startup: Electrical meter helpful but not required ESTIMATED TIMELINE: Unpacking: 15 30 minutes Frame Mounting: 0.5 2.0 hours Fluid Connections: 0.5 2.0 hours Motor & Valve Wiring: 1 4.0 hours Startup & adjustment: 1.5 6.0 hours UNPACKING The AQUA-LAB is shipped in a wooden crate for the purpose of protection. Before unpacking, be sure that the AQUA-LAB is on a level-flat surface. To unpack, perform these steps: 1. Open the crate using a drill with Phillips bit or Phillips head screwdriver 2. Cut the cellophane off of the AQUA-LAB by using a utility knife. Be sure to cut either at the corners or in an area where the knife will not damage the AQUA-LAB. 3. Using an adjustable wrench, un-bolt the AQUA-LAB from the pallet. 4. Lift the AQUA-LAB from the pallet. Use assistance if necessary. 5. Dispose of pallet, cellophane and additional packaging materials. Hydra-Flex, Inc. 2017 Page 2
LOCATION AND MOUNTING **When selecting a location for any Aqua-Lab system make sure to consider the proximity to feed water, power supply, and the control cabinet that the valve signals will need to be wired from (or a junction box with the appropriate signals wires) as well as space near the system to store chemical containers. SPACE REQUIREMENTS: Aqua-Lab Systems TXF Model 3 x 3 footprint with 5 Clearance TXW Model 2 wide x 4.5 high of wall space AX Model 3 wide x 2 high of wall space BX Model 1.5 wide x 2 high of wall space Pump Assemblies (For TXW, AX, and BX Models) Pumps need to be within 3 of the system to allow connection of the two with just the included connection hose Single Pump 4 x 1 wall or floor space Dual Pump Wall mount 4 x 2.5 of wall space Dual Pump Floor skid 4 wide x 1.5 deep footprint with 4 of Clearance Electrical Enclosures Motor Starter (TXW, AX, and BX with Wall mount pump assembly) 1 wide x 1.5 high of wall space VFD Motor Controller (TXW, AX, or BX with Wall mount pump assembly) 1.5 wide x 2 high of wall space Terminal Box (Optional Item used if 30 signal cables do not reach car wash control cabinet) 1 wide x 1 high of wall space MOUNTING OF COMPONENTS: Aqua-Lab Systems TXF Position on the floor in optimal location, can be anchored with included anchor feet TXW Mount to concrete or cinder block wall with 4 concrete anchors AX Mount to concrete or cinder block wall with 4 concrete anchors BX Mount sturdy wall with 4 appropriate anchors Pump Assemblies Does not apply to TXF Single Pump Mount pump flange to concrete or cinder block wall or concrete floor with 4 concrete anchors **Needs to be within 3 of the Aqua-Lab system to connect them with the included connection hose Dual Pump Wall mount Mount to concrete or cinder block wall with 4 concrete anchors **Needs to be within 3 of the Aqua-Lab system to connect them with the included connection hose Dual Pump Floor skid Position on the floor near the feed water connection **Needs to be within 3 of the Aqua-Lab system to connect them with the included connection hose Electrical Enclosures Motor Starter (Pre mounted to the Frame for TXF) for other systems mount to the wall with 4 appropriate anchors VFD Motor Controller (Pre mounted to the Frame for TXF) for other systems mount to the wall with 4 appropriate anchors Terminal Box (Accessory) Mount to wall with 4 appropriate anchors **Location will depend on the position of the Aqua-Lab system and its proximity to the car wash control cabinet Hydra-Flex, Inc. 2017 Page 3
FEED WATER CONNECTION **Prior to connection, please ensure that the feed lines are free of construction debris by flushing out the piping. Main Water Supply Line Size: AX and BX Models: 1 Female NPT; TXF and TXW Models: 1-1/2 Female NPT Keep at least 2 PSI in supply line when pump is in operation Maximum inlet pressure is 80 PSI If the pumps are fed from a tank, the water level must be at least 54 above pump at all times CHEMICAL LINE CONNECTIONS Chemical Inlet Connections Chemical tube recommendation: 1/4 ID Flexible PVC Tubing (Chemical Line Tubing) Run chemical line from storage container through the chemical access holes (Smaller diameter holes) and connect directly to the hose barb on the injector ensure that a foot valve or similar check valve/screen is attached at the end of the line in the storage container. Chemical Solution Connections Solution tube recommendation: 1/2 OD Poly Tubing Adapt hose to chemical injector using customer preferred connection type 3/8 & 1/2 OD Tube Push Fittings are provided Feed hose through solution outlet holes (Larger diameter holes) Metering tips will need to be installed to set dilution ratio - see Operation section below PNEUMATIC CONNECTIONS **IF AIR IS NOT REQUIRED FOR YOUR AQUA-LAB, PLEASE SKIP THIS SECTION Pneumatic Utility Connections: Flow and Pressure: 20 CFM, 100 PSI Max (Primary Regulator Factory Set, do not adjust) Incoming Connection Type and Size: 3/8 OD Hose Push Fitting Filter Included: Yes Regulator Included: Yes (Primary Regulator Factory Set, do not adjust) Lubricator Included: No Outgoing Connection Type and Size: 1/4 OD Hose Push to Connect Air Pressure Control: Individual Adjustable Regulators Air Flow Control: No **If there are unused air ports, either screw out the individual line regulator until air no longer flows or insert supplied plugs Hydra-Flex, Inc. 2017 Page 4
ELECTRICAL CONNECTIONS **Use appropriate table below based on if your system has a Current Sensing and Timer Relays See Figure below to determine type of system. Timer Relay Current Sensing Relay Solenoid Valve Signal Connection **WITH CURRENT SENSING AND TIMER RELAYS STATION OR USE M12 LABEL ON BOX LABEL MAIN TRUCK CABLE WIRE COLOR Solenoid Valve Signal Connection Without Current Sensing and Timer Relays MANIFOLD POSITION* Ground N/A Green/Yellow N/A DO NOT USE N/A Blue N/A Hot / + N/A Brown N/A Station 1 1 White 1 Station 2 2 Green 2 Station 3 3 Yellow 3 Station 4 4 Grey 4 Station 5 5 Pink 5 Neutral / Common 6 Red N/A STATION OR USE M12 LABEL ON BOX LABEL MAIN TRUCK CABLE WIRE COLOR MANIFOLD POSITION* Ground N/A Green/Yellow N/A Neutral / Common N/A Blue N/A DO NOT USE N/A Brown N/A Station 1 1 White 1 Station 2 2 Green 2 Station 3 3 Yellow 3 Station 4 4 Grey 4 Station 5 5 Pink 5 DO NOT USE 6 Red N/A Hydra-Flex, Inc. 2017 Page 5
**Manifold Positions Numbered from Left to Right Pump Power Connection and Signal Connection **208/230V or 480V 3-Phase Power required Motor Starter Version If receptacle plug accessory is included, simply plug the system into the wall outlet Wire each leg of the in coming power to the terminals labeled L1in, L2in, and L3in in the lower left of the enclosure. Make sure to follow all applicable electrical codes. VFD Version If receptacle plug accessory is included, simply plug the system into the wall outlet Wire each leg of the in coming power to the Main power switch in the top right of the enclosure, screw terminals labeled L1, L2, and L3. Make sure to follow all applicable electrical codes. PUMP PRIMING INSTRUCTIONS OPERATION 1. Refer to section II-g to ensure all electrical connections are complete. 2. Connect supply water with a 1 (AX and BX Models) or 1-1/2 (TX Model) Inlet Line and open feed line (Minimum 2 psi required) 3. Pull each pump discharge quick-connect until a steady stream of is flowing, and then reconnect. 4. Start the pumps one at a time using the motor starter. Ensure that pump rotation is correct as indicated on pump and that 200 psi can be reached. 5. TX Model: Slowly open the priming ball valve located off the end of the distribution block and allow water to flow until steady, then close the valve (a hose could be connected to the valve to the drain to avoid excessive water on the floor) 6. AX and BX Models: With the pump off disconnect the high pressure line to the AquaLab at the quick disconnect and point in a safe direction, while holding the line to control it start the pump and allow water to flow until steady. 7. Close the ball valve (TX Model) or reconnect the high pressure line at the quick disconnect (AX and BX Models) 8. Confirm that the pumps can obtain 200 psi and that the pump housing is cool to the touch after a minute in operation. 9. If pump does not prime, repeat steps 3-6!!Pay close attention to the temperature of the pump housing, if it starts getting hotter than the supply water then it is likely that the pump did not prime correctly!! *WARNING* If the pumps do not prime correctly they will heat up and it will cause damage to the pumps. WATER FLOW RATE AND CHEMICAL DILUTION SET UP For each of the chemicals that the Aqua-Lab is delivering to the car wash bay follow the steps outlined below to set the overall flow rate and chemical dilution. NOTE: you will need to know the target flow rate and chemical dilution (concentration) prior to setting up each chemical. Hydra-Flex, Inc. 2017 Page 6
1. Using the Nozzle Size chart in the Appendix of this manual, follow the Feed Pressure column down to 200 (the operating pressure of the Aqua-Lab System). 2. Find the flow rate to the right of 200 that is closest to the desired target flow rate; from there follow that column back to the top of the chart to find the appropriate Nozzle size. 3. Using the Chemical Metering Rate chart in the Appendix of this manual, find the flow rate along the top that is closest to the flow rate you just determined in step 2 above. 4. Follow that column down until you find the dilution ratio (concentration) that is closest to the target value, then look to the Left of the chart to see which metering tip it corresponds to. NOTE: It may be necessary to change to a different injector s size based on the spray pattern and delivery of chemical to the vehicle. In that situation use the Nozzle size chart to determine the new flow rate at 200 psi and repeat steps 3 and 4 above to set the chemical usage. NOTE: The dilution ratios (concentrations) given in the Chemical Metering Rate Chart are based on drawing water through the tips. Some adjustments to a tip larger or smaller may be required due to the different of viscosities of the chemicals and water. POST INSTALLATION VACUUM & BACK PRESSURE CHECK If the spray nozzles on the arch are too small for the injector chosen, the back pressure put on the injector may cause the vacuum to not function and chemical will not be pulled The checks below are intended to help identify any potential issues that would cause the injector not to function correctly CHEM-FLEX INJECTOR VACUUM CHECK 1. At the Chem-Flex Injector, remove the chemical feed line from the injector hose barb. 2. Attached the tubing of the vacuum gauge to the Chem-Flex hose barb. 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 ( ) 18 in Hg 4. Repeat steps 2-4 for each chemical lane that a vacuum reading is needed for. 5. Once testing is complete, turn off the Aqua-Lab pump from the main car wash control cabinet. CHEM-FLEX INJECTOR VACUUM CHECK Back Pressure is defined as the pressure that is created between the injector and the arch nozzles. It is caused by the chemical solution from the injector trying to push its way through the nozzle, the smaller the nozzles the harder it is to push through and consequently higher back pressure 1. Disconnect the outlet hose from the Chem-Flex injector that a back pressure reading will be taken for. 2. Connect the back pressure gauge assembly to the outlet of the Chem-Flex injector. 3. Connect the hose to the arch to the other end of the back pressure gauge assembly. **Make sure all hose barb fittings are secured with hose clamps. 4. Turn on the Aqua-Lab pump and the solenoid valve for the Chem-Flex being tested from the main car wash control cabinet The back pressure should not exceed 33% of the feed pressure (for the Aqua-Lab with the feed pressure set to 200 psi the back pressure should not exceed 66 psi). 5. Turn off the Aqua-Lab pump and solenoid valve at the main car wash control cabinet. 6. Remove the back pressure gauge assembly from the injector and reconnect the hose to the arch. **Make sure all hose barb fittings are secured with hose clamps. 7. Repeat steps 1-5 for each injector that a back pressure reading is needed for. Hydra-Flex, Inc. 2017 Page 7
INDIVIDUAL INJECTOR FLOW RATE MEASUREMENT 1. Attach a short section of tubing (3-5 ft) to the outlet of the injector that you want to measure the flow rate of. 2. Turn on the Aqua-Lab pump and the solenoid valve for the Injector being tested. If possible have someone assist by turning them on while you keep the water from the short section of hose pointed in a safe direction. 3. Using a 2 liter graduated cylinder (or other large graduated cylinder) and a stop watch (watch or cell phone with a stop watch) Make sure the graduated cylinder is empty and that the stop watch is cleared. Direct the flow of water from the tube into the graduated cylinder and start the stop watch the instant you start adding water to the cylinder. Stop the timer when the cylinder is at least half full, preferably at a whole number level (ie. 1 liter, 2 liters) Divide the number of liters by the time in seconds then multiply by 15.85 this will result in how many Gallons per minute (GPM) TROUBLESHOOTING The AQUA-LAB is supplied with the following tools to assist in set up and troubleshooting: Vacuum gauge for checking the vacuum at the chemical injector hose barb, Back Pressure Gauge for measuring back pressure downstream of the injector. PROBLEM POTENTIAL CAUSED SOLUTIONS Pump Operates, but delivers little or no water Pump won t start or run at full speed Excessive Noise from Pump Pump Leaks Injector is not drawing chemical - Passes Vacuum Pressure check test Inlet Restriction Low line voltage Inadequate water supply Undersized piping Leak on the Inlet side Worn or defective pump parts Pump not primed Incorrect Motor rotation Blown fuse or circuit breaker Defective Motor Starter contactor Incorrect Motor Voltage Defective motor Pump components damaged Pump not secured firmly Restricted Inlet Cavitation (Sounds like marbles in pump) Worn mechanical seal Worn o-ring seals Clogged chemical feed Check all in-line filters and inlet plumbing for restrictions 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 See priming instructions Reverse motor rotation by interchanging any two leads Replaced fuses or close circuit breaker Replaced motor starter contactor Voltage must be within 10% of motor rated voltage Replace motor Replace worn part or entire pump Secure properly Clean or correct restriction Increase inlet size Replace shaft seal Replace Check chemical hose, foot valve, metering tip and hose barb for debris or clogs Hydra-Flex, Inc. 2017 Page 8
PROBLEM POTENTIAL CAUSED SOLUTIONS Injector is not drawing chemical - Fails Vacuum Pressure check test System won t regulate up to 200 psi Flow at arch is too low No flow from injector Valve stuck open Staying open when signal is off Too much back pressure on injector Clogged injector check valve Clogged injector nozzle Defective Injector Debris in regulator Opening to many valves at once Pump not primed Defective Check Valve Defective Regulator Defective Pump Incorrect Injector Flow Rate Selection System pressure too low Downstream pluming restrictive Solenoid valve malfunction Clogged Injector No water supply Debris in valve seat Perform back pressure check test outlined in Section IV if this manual. If the result is higher than 66 psi then Increase arch nozzle size or quantity, use larger tubing, or use a smaller flow injector Blow compressed air through the chemical hose barb on the injector to remove debris Remove injector and blow out any debris with compressed air If Vacuum check fails but Back Pressure is less than 66 psi, replace the injector Remove regulator and clean out debris System is limited to opening up to 8 valves at once or pressure will be greatly affected by so much demand Follow priming instructions Replace check valve if broken Replace Regulator Replace Pump Replace with desired injector size Ensure system pressure is set at 200 psi Perform Back pressure test outlined in Section IV of this manual, if over 66 psi, increase tube size and reduce elbows, turns or other restrictive plumbing Ensure valve is receiving the correct electrical signal and voltage Disassemble valve and clean out debris (See valve replacement instructions) Remove injector and blow out debris with compressed air Check that the system has a supply of water Remove and clean valve (See valve replacement instructions) VALVE REPLACEMENT INSTRUCTIONS Remove malfunctioning valves from the manifold making sure to unscrew it from the larger steel hex closest to the plastic body. On a clean work surface disassemble the valve assembly. Be cautious with the small components and noting how it is assembled. Inspect for debris that could interfere with the valves operation, paying particular attention to anything blocking the two small holes through the valve piston (2nd part from the left in the image below). For and correct assembly reference the image below. Hydra-Flex, Inc. 2017 Page 9
APPENDIX: 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 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.00 3.25 3.75 4.50 5.50 8.0 10.0 12.0 15.0 Injector Color White Yellow Tan Red Orange Gray Blue Light Blue Light Green Pink Purple Dark Green Black Black Black Black Nozzle Size 0.029 (0.7 mm) 0.040 (1.0 mm) 0.051 (1.3 mm) 0.057 (1.4 mm) 0.070 (1.8 mm) 0.083 (2.1 mm) 0.086 (2.2 mm) 0.095 (2.4 mm) 0.098 (2.5 mm) 0.106 (2.7 mm) 0.117 (2.9 mm) 0.125 (3.2 mm) 0.161 (4.1 mm) 0.117 (4.5 mm) 0.186 (4.7 mm) 0.207 (5.3 mm) COPPER 1: 57 1: 104 1: 155 1: 195 1: 281 1: 406 1: 468 1: 598 1: 629 1: 739 1: 881 1: 1074 1: 2019 1: 2318 1: 3324 1: 4259 PUMPKIN 1: 43 1: 82 1: 119 1: 126 1: 238 1: 348 1: 398 1: 519 1: 554 1: 647 1: 774 1: 946 1: 1465 1: 1832 1: 2310 1: 3042 BURGUNDY 1: 34 1: 67 1: 97 1: 111 1: 207 1: 304 1: 347 1: 461 1: 495 1: 575 1: 690 1: 845 1: 1244 1: 1670 1: 1975 1: 2469 LIME 1: 28 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 414 1: 447 1: 518 1: 622 1: 764 1: 988 1: 1262 1: 1481 1: 1958 TAN 1: 28 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 414 1: 447 1: 518 1: 622 1: 764 1: 826 1: 1042 1: 1286 1: 1557 ORANGE 1: 23 1: 44 1: 64 1: 78 1: 137 1: 196 1: 215 1: 293 1: 314 1: 365 1: 437 1: 536 1: 751 1: 874 1: 1136 1: 1262 TURQUOISE 1: 17 1: 31 1: 45 1: 55 1: 91 1: 126 1: 134 1: 185 1: 197 1: 230 1: 274 1: 336 1: 561 1: 752 1: 885 1: 1099 PINK 1: 14 1: 24 1: 35 1: 42 1: 68 1: 93 1: 98 1: 130 1: 143 1: 159 1: 188 1: 224 1: 372 1: 473 1: 570 1: 728 LIGHT BLUE 1: 11 1: 17 1: 24 1: 31 1: 47 1: 64 1: 66 1: 93 1: 98 1: 114 1: 136 1: 166 1: 318 1: 406 1: 483 1: 572 BROWN 1: 10 1: 15 1: 22 1: 28 1: 43 1: 58 1: 59 1: 84 1: 88 1: 103 1: 122 1: 150 1: 270 1: 338 1: 408 1: 507 RED 1: 12 1: 17 1: 23 1: 34 1: 45 1: 46 1: 65 1: 69 1: 80 1: 95 1: 116 1: 202 1: 254 1: 306 1: 375 WHITE 1: 12 1: 16 1: 22 1: 31 1: 42 1: 43 1: 61 1: 64 1: 74 1: 88 1: 108 1: 180 1: 226 1: 272 1: 343 GREEN 1: 11 1: 14 1: 20 1: 28 1: 37 1: 38 1: 53 1: 55 1: 65 1: 76 1: 94 1: 160 1: 201 1: 241 1: 300 BLUE 1: 10 1: 12 1: 17 1: 23 1: 30 1: 31 1: 44 1: 46 1: 53 1: 63 1: 77 1: 122 1: 152 1: 185 1: 224 YELLOW 1: 9 1: 12 1: 16 1: 20 1: 22 1: 30 1: 31 1: 36 1: 42 1: 52 1: 80 1: 100 1: 120 1: 148 BLACK 1: 10 1: 13 1: 16 1: 17 1: 23 1: 24 1: 28 1: 33 1: 40 1: 61 1: 77 1: 92 1: 115 PURPLE 1: 6.6 1: 8.3 1: 9 1: 10 1: 13 1: 13 1: 15 1: 17 1: 21 1: 31 1: 39 1: 46 1: 57 GRAY 1: 5.3 1: 6.7 1: 6.9 1: 7.6 1: 9.9 1: 10 1: 11.6 1: 13 1: 16 1: 24 1: 30 1: 35 1: 44 OPEN 1: 4.9 1: 5.3 1: 5.2 1: 6.0 1: 6.1 1: 6.1 1: 7.6 1: 8.3 1: 10 1: 12 1: 15 1: 18 1: 23 3.00 1: 251 1: 503 1: 754 1: 1006 1: 1509 1: 2012 1: 2263 1: 2416 1: 2460 1: 2628 1: 4526 1: 5532 1: 8047 1: 10059 1: 12070 1: 15088 2.00 1: 181 1: 363 1: 544 1: 726 1: 1089 1: 1451 1: 1633 1: 1402 1: 1337 1: 1510 1: 3266 1: 3991 1: 5806 1: 7257 1: 8708 1: 10885 1.00 1: 104 1: 208 1: 311 1: 415 1: 623 1: 831 1: 934 1: 835 1: 778 1: 898 1: 1869 1: 2284 1: 3322 1: 4153 1: 4983 1: 6229 0.75 1: 82 1: 165 1: 247 1: 329 1: 494 1: 659 1: 741 1: 642 1: 668 1: 755 1: 1483 1: 1812 1: 2636 1: 3295 1: 3954 1: 4942 0.50 1: 59 1: 119 1: 178 1: 238 1: 357 1: 475 1: 535 1: 487 1: 496 1: 558 1: 1069 1: 1307 1: 1901 1: 2376 1: 2852 1: 3564 0.25 1: 34 1: 68 1: 102 1: 136 1: 204 1: 272 1: 306 1: 282 1: 304 1: 344 1: 612 1: 748 1: 1088 1: 1360 1: 1632 1: 2040 3/7 polyflow (LLDPE) tubing is required to ensure a seal between the tube wall and the spiral plug. Hydra-Flex, Inc. 2017 Page 10
Figure 1 TERMINAL BOX WIRING INSTRUCTIONS (OPTIONAL) The terminal box offers a simple way to locate the solenoid signal wires. Typically used when an existing system is removed, their signals can be brought to this box and terminated with the Aqua-Lab. INSTALLATION INSTRUCTIONS Figure 2 1. Determine location and hang terminal box. Note that the side of the box with three holes is for the Aqua-Lab control cables (yellow cables), and the side of the box with 5 holes is for the incoming activation signals from the wash controller. Orientate box accordingly and within reach of Aqua-Lab yellow cables 2. Remove Cover and notice the labeling of the terminals (Figure 2). Each chemical bank of the Aqua-Lab is labeled as 1, 2, & 3. For TX model this corresponds to top (1), middle (2), and bottom (3). For AX model this corresponds to left (1) and right (2) Figure 3 3. Bring the yellow cable from the corresponding chemical bank to the box and insert through cable gland as shown. (Figure 3) Figure 4 4. Using a small screwdriver, press into the spring terminal and pull away from the wire terminal to open the spring clamps. Insert the wire that corresponds to the labeled color then release the spring by removing the screw driver (Figure 4) 5. Repeat for all colors labeled. (brown and red are not used) 6. Blue and Green/Yellow are to be wired to the common and ground terminals which are segmented as shown (Figure 5) Figure 5 7. Repeat for all yellow Aqua-Lab cables 8. Individually insert chemical activation signals through cable glands and wire to desired chemical position (see wiring chart in operations manual) (Figure 6). Figure 6 9. Repeat for all chemical signals, only one of the common (blue) and ground (Green/yellow) wires for the signals need to be wired to the corresponding segmented terminals since they should be previously connected at the wash controller. You can wire up to three of the commons and grounds to ensure a redundant connection. 10. Lightly tug on all wires to ensure a good connection. Figure 7 11. Replace Cover and tighten screws Hydra-Flex, Inc. 2017 Page 11
REPLACEMENT PANEL, PUMP, & MCU PARTS LIST - AQUA-LAB AX/BX/TX 4 12 30 16 15 18 or 19 1 6 or 7 3 15 14 1 4 12 25 3 23 22 44 31 33 30 33 26 15 6 or 7 1 3 42 39 38 25 40 or 41 33 30 37 12 Hydra-Flex, Inc. 2017 Page 12
PART NAME PART NUMBER 1 Electric Solenoid Valve Replacement 24 VAC 1001072 24 VDC 1001073 120 VAC 1001074 2 (Shown On Page 4) Hydra-Cannon Valve O-Ring Replacement Kit 1001155 3 Single Black Hydra-Cannon Replacement Assembly 1001384 4 1/2 NPT Hydra-Cannon Manifold End Fitting Assembly 1001556 5 Hydra-Cannon Interface Fitting Assembly 1001557 6 M12 Junction Block - 6 Port, With 30 Homerun Cable 3000412 7 M12 Junction Block - 6 Port, With 100 Homerun Cable 3000750 8 M12 X Din A X Din I Splitter Cable 3000406 9 M12 X Din A X Din I Splitter Cable Medium 3000407 10 M12 X Din A X Din I Splitter Cable Long 3000408 11 M12 X Din A Cable 3000350 12 Outlet Pressure Gauge 0-400 PSI Bottom Mount 3000491 13 1/4 Hose Barb Foaming Air Check Valve 3000819 14 Pneumatic Replacement Valve With Regulator 24 VAC 1001274 24 VDC 1001275 120 VAC 1001276 15 Pisco Regulator Replacement 3000543 16 Primary Air Regulator (BX Only) 1001161 17 Primary Air Regulator (AX & TX) 1001184 18 Primary air regulator Replacement Bowl - Aluminum 3000952 19 Primary air regulator Replacement Bowl - Plastic 3000870 20 1 Male Quick Connect - Brass 3000205 21 1 Female Quick Connect - Brass 3000206 22 3/4 Male Quick Connect - Brass 3000196 23 3/4 Female Quick Connect - Brass 3000197 24 1/2 Male Quick Connect - Brass 3000500 25 1/2 Female Quick Connect - Brass 3000502 26 1 Wye Strainer - 20 Mesh 3000490 27 1 NPT T16 Wye Strainer Screen & Gasket Kit 1001938 28 1/2 Ball Valve - Brass 3000565 29 Thermal Relief Valve - 1/2 NPT 3000323 30 40 GPM Bypass Pressure Regulator - Stainless Steel 3000464 31 Manifold Inlet 1/2 ID Hose X 1/2 NPT Ends - 72 Long 3000579 32 20 GPM Quick Connect Regulator Plumbing Assembly 1001775 33 Replacement/Backup 20 GPM Pump 1001362 34 Outlet Manifold 3000662 35 1 Check Valve - Brass 3000250 36 Quick Connect 9 Cordset For Pump 3000782 37 Quick Connect Pump Plug - Female 3000783 38 Thermal Overload - Sprecher & Schuh 3000862 39 Timer Relay 3000664 40 Current Sensor - AC 3000666 41 Current Sensor - DC 3000866 42 Contactor - Sprecher & Schuh 24 VAC 3000863 24 VDC 3000864 120 VAC 3000865 43 M12 Cordset (Grey) 3000347 44 3/4 x 72 Hose 3000659 Hydra-Flex, Inc. 2017 Page 13
Hydra-Flex, T: 952-808-3640 Inc. 2017 F: 952-808-3650 www.hydraflexinc.com sales@hydraflexinc.com Page 14 4000133 reva0717