CHEMICAL DISPENSING SYSTEM · PANEL 1. Drill 3/8” holes in wall for bottom slots (20” on center...

© Hydra-Flex, Inc. 2019 Page | 1

AQUA-LAB™ MD/XD GEN2 & HDCHEMICAL DISPENSING SYSTEM

User ManualREV K

4000129 revK0119© Hydra-Flex, Inc. 2019


TABLE OF CONTENTS

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

FOR PART NUMBERS & DIAGRAMSVisit www.hydraflexinc.com and click on our Literature Tab located in the top right corner of our

website. Then scroll down to the Sales Literature section & select the Vehicle Wash Catalog.

Specifications 3

LayoutDrawing 4

EstimatedInstallationTimeline 5

InstallationInstructions 5Unpacking 6Location&Mounting 6SystemsWithBoosterPumps&MCU 6SystemsWithVFD&GrundfosPumps 6PneumaticConnections 6

ElectricalConnections(HFIMotorControlUnit) 7

HFIBoosterPump&MCU 9

MCUWiringDiagram(AC) 10MCUWiringDiagram(DC) 12

FeedWaterConnection 14

StartUpBoosterPumps 14

VFDFor20GPMBoosterPump 20

ConnectingandStartUpFor20GPMVFDBoosterPumps 22

HFIGrundfosPump&VariableFrequencyDrive(VFD) 24

VFDWiringDiagram(ForFloorMountedGrundfosPump) 25GrayM12CableDiagramTwoPanels(SingleFloorMountGrundfosPump&VFD) 26

StartUp(SystemsWithVFD&GrundfosPumps) 27VFDModes 28Faults 28

Appendix 29InitialInjectorSetup 29TripleFoamSetup 29OptimizingTheSystem 29NozzleSetup 30ChemicalUsageMeasuring 31RecommendedMaintenance 32AirOperatedValveReplacement 32TroubleShooting 33

PumpIssues 33InjectorIssues 33PressureRegulatorIssues 34Flow/Archissues 34ValveIssues 34VFDIssues 34

InjectorOptimizationTool 35InjectorVacuumCheck 36HighTempShutdownRestartInstructions 36Chem-FlexInjectors-ChemicalDilutionRatios 37RecommendedSetupStartingPoints 38Chem-FlexInjectorPartNumbers 39PressureLossInRunLength 40Aqua-LabWarranty 41Aqua-Lab™-PanelPartsDiagram&List 42Aqua-Lab™-PumpPartsDiagram&List 44Aqua-Lab™-ControlPartsDiagram&List 46TroubleShootingVFDForGrundfos 48TroubleShootingMCUWithHightTempShutdown 49

Aqua-Lab™-PanelPartsDiagram&List 32Aqua-Lab™-PumpPartsDiagram&List 34Aqua-Lab™-ControlPartsDiagram&List 35


SPECIFICATIONSSPECIFICATIONS

*Recommended for use with 30A breaker.

POWER REQUIREMENTS20 GPM (75 LPM) 3 HP

Booster Pump40 GPM (150 LPM) 7.5 HP

Grundfos Pump Air-Actuated Valves

230V/3PH/60Hz/8.9A460V/3PH/60Hz/4.2A

230V/3PH/60Hz/18.6A*460V/3PH/60Hz/8.9A

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

WATER INLET LINES20 GPM (75 LPM) Booster Pump 40 GPM (150 LPM) Grundfos Pump

1” ID 2” ID

SPACE REQUIREMENTS (DEPTH X WIDTH X HEIGHT)40 GPM Grundfos Pump Motor Control Unit VFD MD/XD GEN2/HD Panels

19” x 15” x 42”(49 x 38 x 107 cm)

9” x 14” x 15”(23 x 36 x 38 cm)

14” x 21” x 20”(36 x 54 x 51 cm)

7” x 32” x 34”(21 x 69 x 110 cm)

SPACE REQUIREMENTS WALL-MOUNTED BOOSTER PUMPS (DEPTH X WIDTH X HEIGHT)

1-PumpWall-Mount

2-PumpWall-Mount

3-PumpWall-Mount

12” x 24” x 48”(31 x 61 x 122 cm)

12” x 24” x 48”(31 x 61 x 122 cm)

12” x 36” x 48”(31 x 91 x 122 cm)

SPACE REQUIREMENTS FLOOR-MOUNTED BOOSTER PUMPS (DEPTH X WIDTH X HEIGHT)

1-PumpFloor-Mount

2-PumpFloor-Mount

3-PumpFloor-Mount

12” x 24” x 54”(31 x 61 x 138 cm)

12” x 32” x 54”(31 x 82 x 138 cm)

22” x 32” x 54”(56 x 82 x 138 cm)

OPERATING WATER PRESSURE200 PSI (14 bar) Factory Set

(Assumes 40 PSI (2.8 bar) City Feed)

MAX. WATER SOURCE TEMP.Recommended 110°F (43°C) (max water temp) 140°F (60°C) with Booster Pump

140°F (60°C) with Grundfos Pump

AIR INLET LINE3/8” OD Polyflow per Panel

WATER FILTRATION (SUGGESTED)

50 Micron

AIR OUTLET LINE3/8” OD Polyflow per Application

AIR INLET PRESSURE20 CFM @ 80-120 PSI (5.5-8.3 bar) Dry Air

BACK ROOM AMBIENT AIR TEMPMAX: 130°F (54°C)

*Assuming line length is 50’ (15 m) or less. Refer to user page 30 for recommended size chart for other lengths.

SOLUTION OUTLET LINESUp to 2.25 GPM (8.5 LPM) 3.25 - 4.5 GPM (13.3 - 17 LPM) 5.5 GPM (20.8 LPM) 10.0 - 15.0 GPM (37.9 - 56.8 LPM)

3/8” ID (1/2” OD Polyflow*) 1/2” ID* 5/8” ID* 3/4” ID

OUTLET CONNECTION FROM MANIFOLD20 GPM Booster Pump 40 GPM Vertical Grundfos Pump

.5” FNPT 1” FNPT

WATER SUPPLYMAX FLOW PER PORTMax Flow Per MAM Valve Port 6 GPM

Max Flow Per BAM Valve Port 15 GPM

FLANGE TORQUE20 or 40 GPM Vertical Grundfos Pump

37-44 ft-lbs

PRESSURE TRANSDUCER (VFD)

Pressure Range 0-300 PSI

Set point 200 PSI

Cord Length 7 Meter


LAYOUT DRAWING

***Pump configuration will vary depending on specific order options.

18.8

19.7

41.3 APPROX42 - 46IN

32.7

29.1

PUMP INLET HOSE INCLUDED40 GPM: 2" HOSE INLET PROVIDED

1x 6' QUICK CHANGE FLEXIBLE HOSE WITH REGULATOR AND WYE-STRAINER TOAQUA-LAB WITH 1/2"QUICK-CONNECT ANDBALL VALVE INCLUDEDWITH EACH PANEL

AQUA-LAB XD GEN 2 PANEL

1x 8ft 230V /480V PUMPPOWER CORDINCLUDED WITHEACH PUMP

PUMP STANDLOCATED WITHIN5' OF EACHXD/MD GEN2 & HDBOARD

SIGNAL CONTROL CABLE INCLUDED

PER PRIMARY AIR REGULATOR2x 3/8" POLY FLOW AIR INLET TUBINGPROVIDED BYOTHERS (100 PSI MAX)

4x TAPCON ANCHORSINCLUDED FOR EACH HD/XD PANEL

VFD BOXLOCATED WITHIN 6' OF PUMP MOTOR AQUA LAB 3 PHASE 480V OR 230V POWER IN PROVIDED BY OTHERS

2x 20' SIGNAL WIRE TO AQUA-LAB INCLUDED

4X 3/8 CONCRETE ANCHORS INCLUDED WITH EACH PUMP STAND

WYE STRAINERINTEGRATED INTOOULET MANIFOLD

PRESSURETRANSDUCERCABLE 10 FT

40 GPM: 2"NPT HOSEBARB TO CONNECT TOWATER FEED

PRESSURETRANSDUCERCABLE

POWERFROMWALL

CONNECTTO PUMP

18.8

41.3

40 GPM PUMP

19.7

19.7 20.9

18.1 12.2

VFD BOX


WHO TASK EST. TIME

DISTRIBUTOR MONITOR&RECORDPERFORMANCE 2HR/WK

DISTRIBUTOR MAINTENANCE PER SCHEDULE OR AS NEEDED

POST INSTALLATION

TOTAL HOURS SPENT

INSTALLATION

TOTAL CUSTOMER 1 HR

TOTAL DISTRIBUTOR/TECHNICIAN 15 HR

TOTAL ELECTRICIAN 4 HR

TOTAL PLUMBER 4 HR

PRE-INSTALLATION

ESTIMATED INSTALLATION TIMELINE

WHO TASK EST. TIME

DISTRIBUTOR&CUSTOMER DETERMINE LOCATION TO INSTALL EQUIPMENT 1 HR

PLUMBER INSTALLWATERSUPPLYLINE 4 HR

ELECTRICIAN INSTALL ELECTRICAL SUPPLY LINE 4 HR

TECHNICIAN LABELALLCONTROLLERRELAYSATCONTROLLER 1 HR

TECHNICIAN RUNSOLUTIONANDAIRLINES(IFNECESSARY) 5HR

TECHNICIAN INSTALL AIR SUPPLY LINE 1 HR

TOTAL LABOR HOURS 16 HRS

WHO TASK EST. TIME

DISTRIBUTOR/TECHNICIAN HANG EQUIPMENT 1 HR

TECHNICIAN CONNECTWATER,AIRANDSOLUTIONLINES 1 HR

TECHNICIAN CONNECTCONTROLLEADSTOMAINCONTROLLERORJUNCTIONBOX 2 HR

DISTRIBUTOR/TECHNICIAN STARTUP(INJECTOR,METERINGTIPANDNOZZLESELECTION) 3HR

DISTRIBUTOR/TECHNICIAN DOCUMENT CONFIGURATION 1 HR

TOTAL LABOR HOURS 8 HRS

InstallationtakesapproximatelyONEday.Anelectricianandaplumberareneededforhalfaday.

General Skill Level• Mechanical:Basic-mountingequipment• Electrical:Advanced-threephasepowerandcontrolsknowledge(localcodesknowledgerequired)• Plumbing:Moderate-principalsupplylinerequired• Pneumatic:Basic-pneumaticutilityconnectionrequired• ChemicalKnowledge:Moderate-chemicaltitrationsrequired

INSTALLATION INSTRUCTIONS

• Hammer

• Tapemeasure

• Level

• Utilityknife

• Wirestripper

• Socketset

• Adjustablewrench

• Screwdriverset

• Teflontape

Tools & Equipment Needed:• DrillwithPhillipshead

• Concretedrillbit3/8”

• Concretedrillbit5/32”

Useful Tools:• MultiMeter


UNPACKINGWhenunpackingyourAqua-Labbesurenottodiscardthemanualoranyaccessories.Inspecttheshipmentforanydamageormissingcomponents.Ifpumpsareincludedwithorder,takecaremovingthepump(s).Utilizeproperliftingtechniqueandmechanicalassistanceifnecessary.

LOCATION & MOUNTING **IflocationwasnotidentifiedduringthePre-InstallationProcess,makesuretoconsidertheproximitytofeedwater,powersupply,andthecontrolcabinetaswellasspacenearthesystemtostorechemicalcontainers.Mountbaseofpanel32”fromfloorforeasyinjectoraccess.

***See drawing in reference for general layout

AQUA-LAB MD/XD GEN2 HD (WALL MOUNT)1. Drill(4)5/32”holesonthewall.163/8”wide,275/8”tall.

2. PressAqua-Labboardtightagainstthewall.

3. Screwin3/16”concretescrewswithawasher.

SYSTEMS WITH BOOSTER PUMPS & MCU PUMP ASSEMBLY - NEED TO BE WITHIN 6’ OF FURTHEST AQUA-LAB PANEL1. Drill3/8”holesinwallforbottomslots(20”oncenterpumpnosedown,

3.5”oncenterpumpnosesideways-dualstand).

2. Insertconcreteanchors,setpumponboltsandtightendown.

3. Holdpumpstandinplace,drilltopholes,insertanchorsandtighten.

MOTOR STARTER1. Mounttothewallwith4appropriateanchors.

SYSTEMS WITH VFD & GRUNDFOS PUMPS1. Before bolting components down, ensure the water lines, electrical

cables, etc. have enough length to connect.

2. Removepumpfrompackaging.

3. Locatepumpindesiredlocation.

4. Securelyanchorpumptoconcretefloor.

5. MountVFDtothewall.

PNUMATIC CONNECTIONS• Connectpre-run3/8”ODpolyfeedlinetopushconnectfittingonthe

sideoftheprimaryregulator(orasrequired).

• Connect1/2”ODpolylinesfromarchtoeachportthatwillbefoaming(or as required, see page 40).

**If there are unused air ports, counter-clockwise turn the individual line regulator until air no longer flows.


7 PORT AQUA-LAB (HFI MCU STARTER/VFD)

5 PORT AQUA-LAB (HFI MCU STARTER/VFD)

ELECTRICAL CONNECTIONS (HFI MOTOR CONTROL UNIT)a. Wire homerun control cables to car wash control panel. Manifold position below designates which Valve port is associated to what color wire.

• Example: if you want Presoak 1 to be on manifold port 2, connect the green wire to your controller relay for Presoak 1.

Valve Port 7: BlackValve Port 6: RedValve Port 5: PinkValve Port 4: GreyValve Port 3: YellowValve Port 2: GreenValve Port 1: White

Valve Port 5: PinkValve Port 4: GreyValve Port 3: YellowValve Port 2: GreenValve Port 1: WhiteNeutral / Common: Red

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!).

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!).

***DO NOT WIRE CONSTANT HOT FROM ONE LEG OF 3 PHASE POWER***


2. ELECTRICAL CONNECTIONS (ONLY FOR SYSTEMS RUNNING WITH NON HFI MCU)a. Connect yellow homerun control cables to car wash control panel.

• Manifold position below designates which port is associated to what color wire.• Example: if you want Presoak 1 to be on manifold port 2, connect the green wire to your controller

relay for Presoak 1.(Left to right on water manifold, and left to right on air valves)

b. Wire each leg of power from your starter to each pump.i. See diagram on pump for wiring schematic or pump manual.

7 PORT AQUA-LAB (NON-HFI MOTOR CONTROL UNIT)

5 PORT AQUA-LAB (NON-HFI MOTOR CONTROL UNIT)

Valve Port 7: BlackValve Port 6: RedValve Port 5: PinkValve Port 4: GreyValve Port 3: YellowValve Port 2: GreenValve Port 1: White

ONLY FOR SYSTEMS RUNNING WITH NON HFI MCU

Valve Port 5: PinkValve Port 4: GreyValve Port 3: YellowValve Port 2: GreenValve Port 1: WhiteDo Not Use - Red (Cap With Wire Nut)

Neutral / Common: BlueGround: Green / Yellow

Do Not Use - Brown (Cap With Wire Nut)

Make sure all BROWN & RED wires are separately capped with wire nuts so that they do not touch any other electrical conductive objects (One Wire Per Nut!).

Make sure all BROWN & VIOLET wires are separately capped with wire nuts so that they do not touch any other electrical conductive objects (One Wire Per Nut!).

***DO NOT WIRE CONSTANT HOT FROM ONE LEG OF 3 PHASE POWER***


HFI BOOSTER PUMP & STANDARD MCU(SINGLE SOURCE / SINGLE PUMP SHOWN)

Timer Relay

Contactor

Contactor

Thermal Overload

Thermal Overload

Temperature Shutdown Relay

Temperature Shutdown Light

Smart Relay

Current Switch

Current Switch

3 Phase Disconnect

3 Phase Disconnect

Quick Connect Pump Plug Female

Quick Connect Pump Plug Female

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

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

FOR PART NUMBERS & DIAGRAMS

Visit www.hydraflexinc.com and click on our Literature Tab located

in the top right corner of our website. Then scroll down to the Sales Literature section & select

the Vehicle Wash Catalog.

HFI STANDARD MCU & BOOSTER PUMP SECTION

Wye-Strainer

Pump Outlet Feed Line To MD Panels

Bypass Pressure Regulator

Back-up Pump

Temperature Switch

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

MCU WITH SMART RELAY

MCU WITH OUT SMART RELAY


HFI STANDARD MCU (WITHOUT SMART RELAY) & BOOSTER PUMP SECTION

15

A1B1

1618 A2

TIMER

RELAY

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

ACCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FROM

BREAKER

CONTRO

L VOLTAGE

24/120VAC SINGLE SOURCE SINGLE PUM

P3 PHASE

24/120VAC SINGLE SOURCE SINGLE PUM

P

4000149_RevC0118

34

RELAY 1

34

15

A1B1

1618 A2

TIMER

RELAY

112223

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

ACCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1P1

RELAY 1

TS2TS1

112223

TS2TS1



34

34

34

34

15

A1B1

1618 A2

TIMER

RELAY

15

A1B1

1618 A2

TIMER

RELAY

TS3TS4

112223

3A

TS2TS1

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

RELAY 2

845113

14129

ACCURRENTSENSO

R

ACCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1P1

P2

15

A1B1

1618 A2

TIMER

RELAY

15

A1B1

1618 A2

TIMER

RELAY

TS3TS4

112223

3A

TS2TS1

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

RELAY 2

845113

14129

ACCURRENTSENSO

R

ACCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FROM

BREAKER

RELAY 2

RELAY 2

RELAY 1

RELAY 1

CONTRO

L VOLTAGE

24/120VAC DUAL SOURCE DUAL PUM

P3 PHASE

24/120VAC DUAL SOURCE DUAL PUM

P

4000150_RevC0118



15

A1B1

1618 A2

TIMER

RELAY

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

DCCURRENTSENSO

R

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FROM

BREAKER

CONTRO

L VOLTAGE

24VDC SINGLE SOURCE SINGLE PUM

P3 PHASE

24VDC SINGLE SOURCE SINGLE PUM

P

34

RELAY 1

34

15

A1B1

1618 A2

TIMER

RELAY

112223

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1P1

RELAY 1

TS2TS1

112223

TS2TS1

DCCURRENTSENSO

R

34

21

5

4000147_RevC0118



ACCURRENTSENSO

R

ACCURRENTSENSO

R

34

21

53

42

15

34

34

15

A1B1

1618 A2

TIMER

RELAY

15

A1B1

1618 A2

TIMER

RELAY

TS3TS4

112223

3A

TS2TS1

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

RELAY 2

845113

14129

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1P1

P2

15

A1B1

1618 A2

TIMER

RELAY

15

A1B1

1618 A2

TIMER

RELAY

TS3TS4

112223

3A

TS2TS1

3 PHASE

DISCONECT

1

6 3

4 5

2 1

63

45

2

RELAY 1

845113

14129

RELAY 2

845113

14129

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.97

98N.O

.

THERMAL

OVERLO

AD

2 T16 T3

4 T2

CONTACTO

R

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FROM

BREAKER

CONTRO

L VOLTAGE

RELAY 2

34

RELAY 2

34

RELAY 1

RELAY 1

DCCURRENTSENSO

R

DCCURRENTSENSO

R

34

21

53

42

15

3 PHASE24VDC DUAL SO

URCE DUAL PUMP

24VDC DUAL SOURCE DUAL PUM

P4000148_RevC0118


HFI STANDARD MCU (WITH SMART RELAY) & BOOSTER PUMP SECTION

CON

TROL VO

LTAGE

24/120VAC SING

LE SOURCE SIN

GLE PUM

P3 PH

ASE24/120VAC SIN

GLE SO

URCE SING

LE PUMP

3 PHASE

DISCO

NECT

1

6

3

4

5

2 1

6

3

4

5

2

ACCURREN

TSEN

SOR

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

34

RELAY 1

SMA

RT_4000149_RevA0618

PS1TS11+1+1+1+2-2-2-3

LN

NI1

I2I3

I4I5

I6I7

I8

12

Q1

12

Q2

12

Q3

12

Q4

SMART

RELAY

P1P1

3 PHASE

DISCO

NECT

1

6

3

4

5

2 1

6

3

4

5

2

ACCURREN

TSEN

SOR

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FRO

M BREAKER

34

RELAY 1

PS1TS11+1+1+1+2-2-2-3

LN

NI1

I2I3

I4I5

I6I7

I8

12

Q1

12

Q2

12

Q3

12

Q4

SMART

RELAY



CON

TROL VO

LTAGE

24/120VAC DUAL SO

URCE DUAL PUM

P3 PH

ASE24/120VAC D

UAL SOURCE D

UAL PUMP

3 PHASE

DISCO

NECT

1

6

3

4

5

2 1

6

3

4

5

2

ACCURREN

TSEN

SOR

ACCURREN

TSEN

SOR

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FRO

M BREAKER

34

34

RELAY 2

RELAY 1

TS1TS21+1+1+1+2-2-2-

PS2PS1

33A

LN

NI1

I2I3

I4I5

I6I7

I8

12

Q1

12

Q2

12

Q3

12

Q4

SMART

RELAY

34

34

TS1TS21+1+1+1+2-2-2-

PS2PS1

33A

3 PHASE

DISCO

NECT

1

6

3

4

5

2 1

6

3

4

5

2

ACCURREN

TSEN

SOR

ACCURREN

TSEN

SOR

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1

P2

RELAY 2

RELAY 1

SMA

RT_4000150_RevA0618

LN

NI1

I2I3

I4I5

I6I7

I8

12

Q1

12

Q2

12

Q3

12

Q4

SMART

RELAY

P1



CON

TROL VO

LTAGE

24VDC SIN

GLE SO

URCE SING

LE PUMP

3 PHASE

24VDC SIN

GLE SO

URCE SING

LE PUMP

3 PHASE

DISCO

NECT

1

6

3

4

5

2 1

6

3

4

5

2

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FRO

M BREAKER

SMA

RT_4000147_RevA0618

34

RELAY 1

DC

CURRENT

SENSO

R

34

21

5

PS1TS11+1+1+2-2-2-3

LN

NI1

I2I3

I4I5

I6I7

I8

12

Q1

12

Q2

12

Q3

12

Q4

SMART

RELAY34

3 PHASE

DISCO

NECT

1

6

3

4

5

2 1

6

3

4

5

2

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

P1

P1

RELAY 1

DC

CURRENT

SENSO

R

34

21

5

PS1TS11+1+1+2-2-2-3

+24VOVOV

I1I2

I3I4

I5I6

I7I8

12

Q1

12

Q2

12

Q3

12

Q4

SMART

RELAY



3 PHASE

24VDC D

UAL SOURCE D

UAL PUMP

CON

TROL VO

LTAGE

24VDC D

UAL SOURCE D

UAL PUMP

3 PHASE

DISCO

NECT

1

6

3

4

5

2 1

6

3

4

5

2

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

POW

ER IN FRO

M BREAKER

DC

CURRENT

SENSO

R

DC

CURRENT

SENSO

R

34

21

53

42

15

34

RELAY 2

34

RELAY 1

+24VOVOV

I1I2

I3I4

I5I6

I7I8

12

Q1

12

Q2

12

Q3

12

Q4

SMART

RELAY

TS1TS21+1+1+1+2-2-2-

PS2PS1

33A

P1

P2

P1

3 PHASE

DISCO

NECT

1

6

3

4

5

2 1

6

3

4

5

2

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

9596

N.C.

9798

N.O

.

THERM

ALO

VERLOAD

2 T16 T3

4 T2

CON

TACTOR

1 L13 L2

5 L313 NO

A1

2 T14 T2

6 T314 NO

A2

DC

CURRENT

SENSO

R

DC

CURRENT

SENSO

R

34

21

53

42

15

34

RELAY 2

34

RELAY 1

SMA

RT_4000148_RevA0618

+24VOVOV

I1I2

I3I4

I5I6

I7I8

12

Q1

12

Q2

12

Q3

12

Q4

SMART

RELAY

TS1TS21+1+1+1+1+2-2-

PS2PS1

2-2-3

3A


FEED WATER CONNECTION**PRIOR TO CONNECTION, ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES

• Connectpre-runmainwatersupplylinetopumpinletwithhosesupplied.

• Singleoperatingpump:1”MNPT

• Dualoperatingpump:1-1/2”MNPT

START UP BOOSTER PUMPS

PUMP MUST BE PRIMED BEFORE OPERATION!WARNING!

1. FLUSHMakesurewatersupplytopumpisturnedon.Openball

valveanddirecttowardadrainorcontainertoremovethe

majorityoftheairfromthepumpuntilasteadystreamof

waterisflowing(approx. 1 min).Thenclosetheballvalve.

2. CHECK ROTATION OpenAqua-Lab™MotorControlUnit(MCU)andensure

3phasedisconnectison.(Note: Door will not open with

disconnect on. Use a 1/4” wrench or crescent wrench to turn

it back on after opening door.) (MCU with blue and black

Eaton disconnect can be opened without shutting off by

depressing button under switch handle. Press small button

with screw driver to bypass disconnect (Image 1).

!WARNING! - ELECTRIC SHOCK HAZARD. HIGH

VOLTAGE PRESENT INSIDE MOTOR CONTROL UNIT -

USE CAUTION!

Startthepumpmomentarilybydepressingthecenterofthecontractor(image 2).

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 2T1, 4T2, and 6T3.

• 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

Image 2

HFI STANDARD MCU & BOOSTER PUMP SECTION


Image 5

Image 6Image 7

!WARNING! RUNNING THE PUMP BACKWARD WILL CAUSE CATASTROPHIC SYSTEM FAILURE! ENSURE THAT PUMP ROTATION IS CORRECT (image 3) asindicatedbythearrowonthecastingofthepumpandthat200psicanbereached.

• If pump cannot regulate to 200 psi, remove pump motor cover and look at shaft to confirm correct rotation.

• Verify pump inlet pressure remains positive when running.

3. CLOSE CABINET Turnon3phasedisconnect,ifhightempswitchispresent,pushtostart(Image 4).

4. PURGE BYPASSStartthepumpandslowlyopenballvalveuntilitiswideopen.Allowtorunfor60secondstoflushlinesandthenclosevalve.

5. CONNECT Connectthepumpoutletlinetothemanifoldandopenballvalve.

6. DOUBLE CHECKConfirmthatthepumpcanobtain200psiwhilefiringsolenoidsandthatthepumphousing(stainless steel tube)iscooltothetouchafteraminuteinoperation.

• If housing is hot or noisy, pump did not prime correctly.

• If pump does not prime, repeat steps 3-5.

• If not at 200 psi and the pump is correctly rotating you may need to adjust the bypass regulator to obtain 200 psi (Image 5).

Verifypumpprime24hoursafteroperationtoensureprimeheld.Paycloseattentiontothetemperatureofthepumpshaft,thewholestainlesssteelarea (Image 6)shouldbethesametemperature.Ifitstartsgettinghotterthanthesupplywaterorgreaterthan137°,thenitislikelythatthepumpdidnotprimecorrectlywhichWILL CAUSE DAMAGE TO PUMPS.Themotorhousing(paintedportion)willbehotduringoperation.

HFI BOOSTER PUMPHFI STANDARD MCU & BOOSTER PUMP SECTION

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

b. Connect the gray M12 cables hanging out of the motor starter box to port 8 “PUMP” on the black M12 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 2T1, 4T2, and 6T3.

• Make sure to follow all applicable electrical codes.


HFI 20 GPM VFD & BOOSTER PUMP SECTION

VFD FOR 20 GPM BOOSTER PUMP

Relay Socket

Power Supply

VFD

Temperature Shutdown Light

Current Switch

3 Phase Disconnect

Quick Connect Pump Plug Female Grey M12 Cables (Carry signal from

M12 distribution block to motor starter that turns on the pump)


HFI BOOSTER PUMPHFI 20 GPM VFD & BOOSTER PUMP SECTION

20 GPM BOOSTER PUMP FOR VFD

Wye-Strainer

Temperature SwitchPressure Transducer

Pump Outlet Feed Line To Aqua-Lab Panels

Quick Connect 9’ Cordset For Pump (Plugs Into Bottom

Of 20 GPM VFD)

Incoming Water


START UP WITH VFD FOR BOOSTER PUMP

PUMP MUST BE PRIMED BEFORE OPERATION!WARNING!

HFI 20 GPM VFD & BOOSTER PUMP SECTION

1. Verifythatthepumpvoltagematchesthesitevoltage

thatwillbesuppliedtothepump.Thereisavoltage

labelonthepumpcordindicatingwhichvoltagethe

pumpiswiredfor.

2. RoutepowerfromsitetoVFDbox.Makesurethatthe

sitepowerbeingsuppliedmatchestheVFDvoltage.

3. Havealicensedelectricianconnect3phasepowertothe

VFD (IMAGE 1).

CAUTION: DO NOT APPLY 460V TO A 230V VFD

4. Routepump(s)powercordtoPowerfastconnector(s)on

VFD (IMAGE 2).

5. Routewatertopump(IMAGE 3).

6. Attachpumpplumbing(IMAGE 4).

7. Primethepump:

8. Attachblackpressuretransducercabletopressure

transducer(IMAGE 7).IfitisadualVFDtherewillbe

twotransducerconnectionsthatwillneedtobemade.

Ensurethetransducersareconnectedtocorrectpumps

(labeledtransduceroneandtransducertwo).

a. Make sure water supply to pump is turned on.

b. Open ball valve to direct toward a drain or container to remove most of the air from the pump until a steady stream of water is flowing (approx. 1 min) (IMAGE 5).

c. Then close the ball valve, connect to panel & open (IMAGE 6).

Image 1

Image 2

Image 3

Image 4

Image 7 Image 5Image 6


9. Connectthehightemperatureswitchfromthepumpto

thematingconnectorfromtheVFD(IMAGE 8).Ifitisa

dualVFDtherewillbetwohightemperatureconnections

thatwillneedtobemade.Ensuretheswitchesare

connectedtocorrectpumps(labeledTemponeand

temptwo).

10. AttachremaininggraysignalcordstotheAqua-LabM12

junctionblocks,positions6and/or8B(IMAGE 9).

Note: the VFD control box has multiple M12 junction

block signal cables attached. If the system does not

require all cords, leave cords coiled up and ensure the

cable ends are capped.

11. After(1)pumpisprimed,(2)outletisconnectedtothe

Aqua-Lab,and(3)VFDiscorrectlywiredwith3phase

power-theVFDmaynowbeturnedon.Verifycorrect

rotationofthepump(s)by:

CAUTION: Wait 10 minutes before modifying any

electrical connection inside the VFD box. This allows

the capacitors to drain stored energy that may cause

personal injury or equipment damage if discharged

incorrectly.

12. SendsignalfromcarwashcontrollertoAqua-Labpanel

toturnonpump

HFI BOOSTER PUMPHFI 20 GPM VFD & BOOSTER PUMP SECTION

a. Pulsing the pump(s) on and off by sending a signal from car wash controller for a chemical function to turn on.

b. Examine the fan by looking downward onto the pump. Verify the fan is spinning in the same direction as indicated on the pump.

c. If pump is rotating backwards, switch any two lines of power at the pump.

a. Verify that 180-200psi water is supplied to the Aqua-Lab panel.

b. Use the up and down arrows on the keypad to increase/decrease pressure if desired.

i. Do this by pressing enter on the main screen

ii. Adjust to desired pressure using the arrow buttons

iii. Press enter again to set pressure

Image 8

Image 9

Image 10


HFI GRUNDFOS PUMP & VARIABLE FREQUENCY DRIVE (VFD)

Pump Power Cord, To Be Wired To VFD

Fan Fuses & Transformer

Fan Filter

Current Switch

VFD

M12 Connections To Junction Block

Gray Cord For Pressure Transducer

Motor Stool For Lifting

Pump Motor

Main Power Fuses

Fan

Incoming Power

ElectricDisconnect

Location For Pressure Transducer,

Temp Switch, Pressure Gauge.

(QTY 3: 1/4” FNPT)

Vent Cap To Prime pump

Embossed Arrow For Motor Direction

Pump Inlet (1.25” ID Hose For 20 GPM, 2” ID Hose For 40 GPM)

Pump Outlet (1/2” FNPT for 20 GPM, 1”

FNPT For 40 GPM)

Wye Strainer Screen (Inside Manifold,

Remove Plug To Clean Strainer Screen)

HFI GRUNDFOS PUMP SECTION


S+ S-S+ S+ S- S-

JumperJumper

NC NC NC DV DV24V

24V

204

217

Jumper Grou

ndJumper

CurrentSwitch

MAINSU1 W1V1

MOTORU2 W2V2 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

Block 1 Block 2

PowerFrom Fuses

24 - 12 = Current Switch

24 - 217 = Pressure Transducer

24 - 204 = Temp Switch or Jumper

Pump

Cap Brown Wire

Transducer: Brown = 24VBlue = 217Shield = Green

Aqua-LabPanel 1

Aqua-LabPanel 2

OptionalTemp Switch

VFD WIRING DIAGRAM(FOR FLOOR MOUNTED GRUNDFOS PUMP)



GREY M12 CABLE DIAGRAM TWO PANELS(SINGLE FLOOR MOUNT GRUNDFOS PUMP & VFD)

Gray Wire

Hom

e Ru

n Ca

ble G

ray

Wire

VFD

To Car Wash Controller

To Power 3PH

Pressure Sensor Wire

Note: Not all gray wireswill be used.

Water InletWater Outlet

Pressure Sensor

Grundfos Pump

LOCREM ?

STOPS START



1. Slideinhexnutsfromplumbingoutletmanifoldintoslotsonpumphousing

2. Fastenoutletmanifoldtopumphousing.Torqueboltsto~40footpounds.Ensuregasketislocatedcorrectly.

3. Verifythatthepumpvoltagematchesthesitevoltagethatwillbesuppliedtopowerthepump.Thereisavoltagelabelonthepumpcordindicatingwhichvoltagethepumpiswiredfor.Motorsareratedfor+10%oftheratedvoltageonthemotornameplate.

4. RoutepowerfromsitetoVFDbox.MakesurethatthesitepowerbeingsuppliedmatchestheVFDvoltage. Note: Do not run pump power cord within 6 ft of sensitive electronics. Route in independent conduit to prevent signal interference.

5. RoutepumppowercordtoVFD.

6. Routewatertopump.

a. Note: for 40 GPM pump, do not plumb any elbows or bends within 20 inches of the pump inlet. b.Note: for 20 GPM pumps, do not plumb any elbows or bends within 13 inches of pump inlet.

7. RoutepumpoutlettoAqua-Labpanel.

8. Primethepumpbylooseningtheventpluglocatedatthetopofthepump.Airwillpurgethroughtheventhole.Pumpisprimedoncewaterbeginstoflowoutofthevent.Tightenventcapplug. a. Disconnect closed ball valve at valve 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.

Fasten outlet manifold to pump housing

Slide Nuts Into Frame

CAUTION: DO NOT APPLY 480V TO A 230VAC VFD.

Main Site Supply PowerWhite to L1, Red to L2, Black to L3

Pump Power CordWhite to U2, Red to V2, Black to W2,

Ground to Grounding screw

Loosen Priming Vent To Purge Air

Pump Is Primed Once Water Begins To Come Out. Close Vent By Tightening Plug

9. Attachgraypressuretransducercabletopressuretransducer.

10. AttachremaininggraysignalcordstoAqua-LabM12junctionblockspositionssixand8B. a. Note: The VFD control box has 3 M12 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)

START UP(SYSTEMS WITH VFD & GRUNDFOS PUMPS):



11. EnsureVFDisintheREMModebyusingthekeypadonthefrontfaceoftheVFD.

12. SEE PAGE 13 FOR INSTRUCTIONS ON WIRING YOUR VFD. YOUR VFD MUST BE WIRED IN ORDER FOR YOU TO VERIFY ROTATION. Verify Correct Rotation (in REM MODE):Pulsethepumponandoffbysendingasignalfromthecarwashcontrollerforachemicalfunctiontoturnon.Examinethefanbylookingdownwardontothepump.Verifythatthefanisspinninginthesamedirectionasindicatedonthemotorcasting.

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 U2 with V2 as shown in the image above in section 5. CAUTION: DO NOT WORK INSIDE VFD BOX UNTIL 10 MINUTES AFTER POWER DOWN.

13. SendsignalfromcarwashcontrollertoAqua-Labpaneltoturnonpump,verifythat180-200PSIwaterissuppliedtotheAqua-Labpanel.Usetheupanddownarrowsonthekeypadtoincrease/decreasepressure.

Press loc/REM Button Until REM Is Shown In The Top Left Of Screen

Direction On Motor Casting Indicating Correct Direction

FAULTSTheVFDhasthefollowingfaultprotectionstokeepthepumpandsystemsafe.Seetablebelow.

FAULT TYPE FAULT CAUSE SCREEN READ OUT

Low Inlet Pressure(FAULT 42)

1. No water supplied to pump inlet.2. Blown fuse on incoming power supply.3. Panel flow set up exceeds pump

performance curve (reduce injector sizes).4. Hose rupture.5. Pump running at low pressure for more

than 1 minute.

High Temperature(FAULT 14)

1. If temperature switch is wired in and the temperature exceeds switch set point, the temperature switch will fault out.

2. If the temperature switch is not installed make sure that there is a solid jumper between terminal block 24V and terminal block 204.

LOCREM ?

STOPS TART

LOC FAULT

INLET LOWRESET EXIT

FAULT 42

LOCREM ?

STOPS TART

REM FAULT

EXT FAULT 1RESET EXIT

FAULT 14

VFD MODESRemote Mode:ThistakesasignalfromacarwashcontrollertoturnonachemicalfunctionwhichtheninitiatestheVFDtostartthepump.TouseREMmode,presstheloc/rembuttonontheleftofthekeypaduntilREMappearsonthetopleftofthescreen.Sendasignalfromthecarwashcontrollertoactivatethepump.Usetheupanddownarrowsonthekeypadtoincrease/decreasepressure.

SAFETYCAUTION: WAIT 10 MINUTES AFTER POWERING DOWN THE VFD BEFORE

WORKING INSIDE THE BOX. THE VFD CONTAINS LARGE CAPACITORS AND 10 MINUTES IS NEEDED TO ALLOW THE CAPACITORS TO SAFELY DISCHARGE.



(Based on field experience this is HFI’s recommended starting point)1. Usingtherecommendedstartingpoint(Page38)orthetargetflowrateandthechemicaldilutions

chart(appendixPage37)installtheappropriateinjectorintoeachport.

2. Connectpre-runsolutionlinestoeachinjectorwiththesuppliedcouplerandpushconnectfitting.

a. Be sure to use Teflon tape when connecting the injector to the coupler and push connect fitting to ensure there are no leaks.

b. Do not over tighten poly fittings or they may crack.

3. Connect¼”polylinesfromeachchemicalcontainertothehosebarbontheappropriateinjector. a. Ensure a foot valve or similar check valve/filter is installed on each line.

i. These must be present or metering tips may clog.4. Meteringtipswillneedtobeinstalledtosetdilutionratio(seeappendixPage37forratiochartsto

determinetip.)

INITIAL INJECTOR SETUP

YourAqua-Labpanelwasdesignwith Tri-Foamcapabilitythebelowinstructionswill showyouhowtosetupyourtriplefoam.

• Yourtriplefoamhasbeensetupfromthe factorytobeinthelastport(furthestleft).

• Insertyourtriplefoammanifoldintothatpositionwithyourselectedinjectorsalreadyinserted.

• Onthetopsideofthepaneltheregulatorswillcontroltheairtoeachofyourtriplefoamcolors.

• Insertyourairlinestothearchintothe bulkheadfittingsonthesideofthepanel.Thebulkheadwillbetheairlinesforeachcolor.

Note: Occasionally if all three regulators are pre-set too high, you may need to lower all three regulators to their lowest setting and then turn them up to the desired pressure.

TRIPLE FOAM SETUP

APPENDIX

A

A

B

B

C

C


What do metering tips do?• Increasesordecreasestheamountof

chemicalinthesolution.

What do nozzles do?• Determinesthepatternandbackpressure

ofthesolution.

APPLICATION OPTIMIZATION(REPEAT FOR EACH APPLICATION)• Application too wet

• Increase foaming air pressure• Reduce injector size (decreases water)• Increase metering tip (increases

chemical)

• Application too dry• Decrease foaming air pressure• Increase injector size (increases water)• Decrease metering tip (decreases

chemical)

• Nozzle sputters• Decrease foaming air pressure• Decrease number of nozzle(s) and/or

size used on arch• Increase injector size (increases water)

• Too much chemical used• Decrease metering tip• Decrease metering tip and injector

size (to maintain desired ratio)

OPTIMIZING THE SYSTEMCONSISTENTLY ACHIEVE THE DESIRED CLEANING AND PRESENTATION/PERFORMANCE USING THE LEAST AMOUNT OF CHEMICAL AND WATERINJECTORS VS. METERING TIPS VS. NOZZLESTHE KEY TO OPTIMIZING THE SYSTEM IS THROUGH TRIAL AND ERROR. DON’T BE AFRAID TO TRY THESE STEPS TO ACHIEVE YOUR IDEAL PERFORMANCEWhat do injectors do?

• Increasesordecreasestheamountofwaterinthesolution.

• No chemical • Check vacuum/back-pressure of

injector for clogging (see page 36 for Injector Vacuum Check Instructions or page 33 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)

NOZZLE SETUP(Optional For Maximized Optimization)

• Usingtherecommendedstartingpoint(appendixpage37)installtherecommendednozzles.• Thismayinvolveremovingandpluggingsomeports.• DuetothelowerwaterusagedeterminedbytheinjectoroftheAqua-Labyouwillneedto

matchtheflowoftheapplicationdevicetotheinjector.• Setupthenozzlespraypatternsto“paint”thecar-slightlyoverlappingeachother.


MINIMUM NUMBER OF NOZZLES NECESSARY WITH FOAMING AIR(Assuming <10 PSI line loss and ~ 40 PSI at the nozzle)

SPRAY NOZZLE SIZE# 2.0 # 3.0 # 4.0 # 5.0 # 6.0 # 7.0 # 8.0 # 9.0 # 10.0

0.25 4 2 2 1 1 1 1 1 10.50 8 5 4 3 2 2 2 1 10.75 13 8 6 5 4 3 3 2 21.0 17 11 8 7 5 5 4 3 31.5 26 17 13 10 8 7 6 5 52.0 35 23 17 14 11 10 8 7 7

2.25 39 26 19 15 13 11 9 8 73.25 56 37 28 22 18 16 14 12 115.5 96 64 48 38 32 27 24 21 198.0 140 93 70 55 47 39 35 31 2810 175 116 87 69 58 49 44 38 3512 209 140 105 83 70 59 52 46 4115 262 175 131 104 87 74 65 57 52

INJE

CTO

R FL

OW

RAT

E @

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 # 10.0

0.25 1 1 1 1 1 1 1 1 10.50 2 1 1 1 1 1 1 1 10.75 3 2 1 1 1 1 1 1 11.0 5 3 2 2 1 1 1 1 11.5 7 5 3 3 2 2 1 1 12.0 10 6 5 4 3 2 2 2 22.25 11 7 5 4 3 3 2 2 23.25 16 10 8 6 5 4 4 3 35.5 27 18 13 11 9 7 6 6 58.0 39 26 19 16 13 10 9 9 7

10.0 49 33 24 20 16 13 11 11 912.0 59 39 28 24 20 15 13 13 1115.0 74 49 35 30 25 19 16 16 14

INJE

CTO

R FL

OW

RAT

E @

200

PSI

(GPM

)

Elbows/Pipe Fittings• Elbowsandotherpipefittingsaddbackpressurebycausingthefluidtochangedirectionand

thuschangingthefluid’smomentum.Trytofindsimplerwaystorouteyourfluidwithoutelbows.

Line Length• Longerlinesaddbackpressureduetotheinherentresistancecausedbyfriction.Seeifyoucan

reducethelinelengthorincreasetheinsidediameter.

CHEMICAL USAGE MEASURINGVERIFY TITRATION OF CHEMICALS BEFORE PROCEEDING1. Setuplabscalewithsmallbucketofchemicaltobemeasured.

2. Putthesuctionlineintothebucket.

3. Runtheapplicationbeingtestedto“prime”theline.(Allairbubblesmustberemovedforaccuracy.)

4. RecordtheInitial Weight fromthescale.(Taringthescalewithweightonthescalecanaffectaccuracy.)5. Runtheapplicationfor1vehicle(ormanuallyforthesameamountoftimeitwouldbeonfor1

vehicle).

6. RecordtheFinal Weightfromthescale.7. SubtracttheInitialWeightfromtheFinalWeighttodeterminetheweightofusedproduct.

8. DividethePer Car Weightingramsbythespecificgravityofthechemicaltodeterminethemillilitersofchemicalusedpervehicle.

9. Repeatforeachchemicalapplication.

0

8

16

24


RECOMMENDED MAINTENANCETHE RECOMMENDED SERVICE AND MAINTENANCE ON THE AQUA-LAB SYSTEM ARE AS FOLLOWS. Monthly

• Check/drainprimaryairregulator/filterseparator.• Checkwaterfilterandreplaceasneeded(ifinstalled).• Checkandcleanwyestrainer.

Semi-Annually• Checkandreplaceinjectormeteringtips.• Inspectandreplacechemicallinesasneeded.• Ensurelinesaretightlysecuredtoinjectorhosebarbs,clip1”offoldhoseasneededthatwas

stretchedbyhosebarb.

Annually• Cleanwaterregulator.• Inspectmotorstarterfordiscoloredwiringand/orburntterminals.Ifidentified,order/install

replacementparts.

1-3 Years• Inspectandreplaceinjectorsasneeded.• Inspectandreplaceasneededmanifoldpistonsando-rings.• Inspectandreplaceasneededmainwaterpressureregulator.

MAM & BAM VALVES REBUILD KIT INSTRUCTIONS

AQUA-LAB™ MD GEN2

& XD GEN2 (MAM) VALVE

ABC

12

AQUA-LAB™ HD & XD GEN2 (BAM) VALVE

ABC

1 2

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).

7. Recommend replacing every 300,000 cycles.


INJECTOR ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONSInjector Is Not Drawing Chemical - Passes Vacuum Pressure Check Cloggedchemicalfeed

Checkchemicalhose,footvalve,meteringtip,andhosebarbfordebrisorclogs.

No Flow From InjectorValvemalfunction,valvenotopening

Ensureminimum60psionprimaryairregulator,ensurevalvereceivingsignal.

Cloggedinjector Removeinjectorandblowoutdebriswithcompressedair.

Nowatersupply Checkthatthesystemhasasupplyofwater.

Injector Is Not Drawing Chemical - Fails Vacuum Pressure Check

ToomuchbackpressureoninjectorCleanorreplacedownstreamcheckvalves,increasenozzlesizeorquantity,uselargertubing,orusesmallerflowinjectors.

CloggedinjectorcheckvalveBlowcompressedairthroughthechemicalhosebarbontheinjectortoremovedebris.

Cloggedinjectornozzle Removeinjectorandblowoutanydebriswithcompressedair.

Defectiveinjector Replaceinjector.

Productspecific-Sonny’sRainBar Removeelbowatinlettofoamgeneratorandremovenozzle.

Manifoldinletclogged(rare)Removeendfittingsandretentionrod.Cleanoutinletholestoallowfullflow.

Injector stainless steel disintegrating Stronghydrofluoricacid CallHydra-Flexandordercompositeversionofinjectors.

PUMP ISSUESTROUBLESHOOTING

PROBLEM POTENTIAL CAUSES SOLUTIONS

Pump Operates, But Only Delivering 100-150 Psi Incorrectmotorrotation Reverserotationbyinterchangingtwoleads.

Pump Operates, But Delivers Little Or No Water

Pumpnotprimed Seepriminginstructions.

Missing1of3phases Wireaccordingtodiagram/checkbreaker(turnoffonback).

InadequatewatersupplyCheckpressureoninletsideofpumptobesurepositivepressureismaintained.

Undersizedpiping Replacewithlargerpiping.

Leakontheinletside Makesureconnectionsaretight.

Wornordefectivepumpparts Replacewornpartsorentirepump,cleanpartsifrequired.

Overheat Light OnInlettemptohigh

Reduceinlettempto110°FMax,injectorflowto10GPMmax.

Injectorflowtoolow Increasecontinuousflowtoatleast3/4GPM.

Pump Will Not Start Or Run AtFull Speed

ConstanthotnotconnectedMakesureconstantcontrolvoltageissuppliedincarwashcontroller.

Blownfuseorcircuitbreaker

Couldbeduetoblownpumpmotor.Trytoturnbreakerbackonorreplacefuse.Ifbreakertripsaftertryingtofiremotoritismostlikelyburnedout.Replacewithnewmotorandpump.

Defectivemotorstartercontactor Replacemotorstartercontactor.

Thermaloverloadsettoolow/tripped Adjustsettingonthermaloverloadtomatchvoltage.

IncorrectmotorvoltageVoltagemustbewithin10%ofmotorratedvoltage.(Checkthatpumpiswiredforcorrectvoltage.)

Defectivemotor Replacemotor.

3phasedisconnectturnedoff Turndisconnecton.

Pumpcomponentsdamaged Replacewornpartorentirepump.

CurrentSensornotseeinganycurrent

Turnononevalveandverifyredlightblinksfast,verifyatleast10wrapsofwirearoundcurrentsensor.


FLOW / ARCH ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS

Flow At Arch Is Too Low

Incorrectinjectorflowrateselection

Replacewithlargerinjector

Systempressuretoolow Ensuresystempressureissetat200psi

Foamgeneratorplugged Ensurecleanedandclear

DownstreamplumbingrestrictiveIncreasesizeofplumbing/tubing,ensurecheckvalvesarecleanedornew,reduceelbowsinlineorotherturnsthatwouldrestrict

VALVE ISSUES

VFD ISSUES


Valve Will Not Open

AirpressuretoolowEnsureprimaryairregulatorreadingatleast60psi,turnupto80-90psiifpossibleandcheckagain.

Internalvalveo-ringjammed/twisted

Removevalvefrommanifold,Carefullyremovetopofvalve (caution – under high spring pressure)pushwhitepistonupwithsmallallenwrenchfromoppositeendandchecko-ringcondition.Replaceandlubricateifneeded.

Valve Leaks Air Or Water Out Top

Internalo-ringsealdamaged/worn

Removevalvefrommanifold,Carefullyremovetopofvalve (caution – under high spring pressure)pushwhitepistonupwithsmallscrewdriverfromoppositeendandchecko-ringcondition.Replacewith018&008VitonO-ringandlubricatewithDow111valvelube.

Valve Remains Open After Signal Is Off

Manifoldpressureisabove230psi Reducepressuretomanifoldto200psioperatingpressure.

Airexhaustmufflerisclogged Replaceexhaustmuffler.


Low Inlet Pressure (FAULT 42)Valve Leaks Air Or Water Out Top

Nowatersuppliedtopumpinlet. Verifywatersuppliedtopumpissufficient.

Blownfuseonincomingpowersupply.

Confirmcorrectelectricalsupplyandconnections.

Panelflowsetupexceedspumpperformancecurve.

Ensuretotalinjectorflowislessthanpumpsystemcanprovide.Reduceinjectorsize(s)ifneeded.

Waterpressureislessthan100psiforlongerthan1minute.

Checksystemforleaksorrupturedhoses.

High Temperature (FAULT 14)

Iftemperatureswitchiswiredinandthetemperatureexceeds180°F,thetemperatureswitchwillfaultout.

Ensureinletwatertemperatureislessthan140°F.

Ifatemperatureswitchisnotinstalled,falsesignaltoVFD.

Ensureasolidjumperbetweenterminalblock24Vandterminalblock204inthecontrolbox.

PRESSURE REGULATOR ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS

System Won’t Regulate Up To 200 Psi

Pumpnotprimed Followpriminginstructions.

Debrisinregulator Removeregulatorandcleanoutdebris.

Motorrotationincorrect Verifyrotation/switch2leads.

OpeningtoomanyvalvesatonceSystemislimitedbysizeofpumpandsizeofinjectors,increaseflowbyaddingsecondarypumpsorreducesize/numberofinjectorsopen.

Defectivecheckvalve(ifapplicable) Replacecheckvalve.

DefectiveRegulator Replaceregulator.

DefectivePump ReplacePump.

PressureTransducerissetincorrectlyorisbroken

RefertoPumpManualtoverifytransducersettingorreplacetransducer.

PressureTransducercableislooseordamaged

Ensuregoodconnectionsorreplacecable.


STEPS:1. Plugtheoptimizationtoolintothe

outletlineofinjectorandconnectsolutionoutputline.

2. TurnonfunctionfromcarwashcontrollertoactuateHydra-Cannonvalvesuchthatfluidisflowingthroughboththeinjectorandinjectoroptimizationtoolandouttotheapplicator.

3. Readinjectoroptimizationtool.

4. Ifthegaugeisinthe“RED ZONE”thebackpressureoftheoutletlineiseithertoolowortoohigh.Seestepsbelowtocorrect. Solution

Output Line

Hydra-Cannon Valve

Injector Optimization Tool

Injector

Chemical Draw Line

Chemical Bucket

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

Backpressurereferstothepressureinthesolutionoutputline.Excessivebackpressureisthemainreasonthatinjectorswillnotdraw.Ifthereiseveranyconcerntowhyaninjectorisnotdrawingchemical,thebestandeasiestwaytodiagnosetheproblemistocheckthebackpressure.Seeinstructionsbelow:

INJECTOR OPTIMIZATION TOOL

BACK PRESSURE TOO HIGH (UPPER RED SECTION):(Back Pressure May Be Affected By One Or Several Of These Things)

1. Foamgeneratorsareclogged/degraded.Cleanorreplacemediaingenerator.2. Injectorflowsizeistoolarge.Godownaninjectorsize(lessGPM).3. Nozzlesizeonthearchistoosmall.Goupinnozzlesize.4. Checkvalvesaredirtyandorfailing.Cleanorreplacecheckvalves.5. Thereisakinkinthelineorexcessfittings(elbowsandreducersincreasethebackpressure).

Checklineandreplaceanykinkedsections.Trytoreducefittings.6. IDoftubinggoingouttothetunnelistoosmall.Goupasizeininsidediameter.7. Checkvalveshavetoohighofcrackingpressure.Replacecheckvalvewithlowerpressurecheckvalve.8. Cleanfootvalve.

BACK PRESSURE TOO LOW (LOWER RED SECTION):(Back Pressure May Be Affected By One Or Several Of These Things)

1. Injectorflowtoolow.Increaseinjectorsize.2. Nozzlesizetoolarge.Reducenozzlesize.


INJECTOR VACUUM CHECK

C

B

(FOR TROUBLESHOOTING INJECTORS) 1. AttheChem-Flexinjector,removethechemicalfeedlinefrom

theinjectorhosebarb.

2. AttachthetubingofthevacuumgaugetotheChem-Flexhosebarb(ImageA).

3. Withthepump(s)on,manuallyactivatethechemicalthatistobetestedatthemaincarwashcontrolcabinet.Aninjectorthatisworkingproperlywillhaveareadinggreaterthanorequalto(≥) 20inHg.

4. Ifvacuumreads<20in/Hg(imageB),removesolutionmetering tip(imageC)andretest. a. If retest vacuum reads >20 in/Hg (image D), The solution metering tip is clogged. Replace the metering tip. b. If Retest vacuum reads <20 in/Hg, continue to STEP 5

5. Removeanozzleonthearchorthechemicalfeedlinefromthefoamgeneratorandretestvacuum. a. If retest vacuum reads >20 in/Hg, back pressure is being created. Continue to STEP 6. b. If back pressure is not still not being created try these steps and retest after each:

1. Clean nozzle tips. 2. Loosely replace media in foam generator. Do not over pack. 3. Decrease air pressure for foaming. 4. Try smaller injector (this will produce less flow and thus less back pressure).

c. If retest vacuum reads <20 in/Hg, replace injector and retest. If vacuum continues to read <20 in/ Hg, call your service provider.

6. Repeatsteps2-5foreachchemicallanethatavacuumreadingisneededfor.

7. Oncetestingiscomplete,turnofftheAqua-Labpumpfromthemaincarwashcontrolcabinet.

A

D

HFI MCU HIGH TEMP SHUTDOWN RESTART INSTRUCTIONS1. Closeballvalveonpanelandquickdisconnecthigh

pressurewaterline.

*** Purge pressure before disconnecting (pressure gauge to read 0 PSI before disconnecting).2. Pointhosetodrainandopenballvalvetopurgehotwater

andcoolpumpforseveralminutes(USECAUTION).

3. Whenpumpissufficientlycooledcloseballvalve,reconnecthose,openballvalveandpressredbuttononMCUtorestart.

4. Determinewhysystemoverheated.Seemanualfortroubleshooting(page33Overheat Light On)

1.

2.

3.


CHEM-FLEX INJECTORS - CHEMICAL DILUTION RATIOS

3.00

”1:

251

1: 5

031:

754

1: 1

006

1: 1

509

1: 2

012

1: 2

263

1: 2

416

1: 2

460

1: 2

628

1: 4

526

1: 5

532

1: 8

047

1: 1

0059

1: 1

2070

1: 1

5088

2.00

”1:

181

1: 3

631:

544

1: 7

261:

108

91:

145

11:

163

31:

140

21:

133

71:

151

01:

326

61:

399

11:

580

61:

725

71:

870

81:

108

85

1.00

”1:

104

1: 2

081:

311

1: 4

151:

623

1: 8

311:

934

1: 8

351:

778

1: 8

981:

186

91:

228

41:

332

21:

415

31:

498

31:

622

9

0.75

”1:

82

1: 1

651:

247

1: 3

291:

494

1: 6

591:

741

1: 6

421:

668

1: 7

551:

148

31:

181

21:

263

61:

329

51:

395

41:

494

2

0.50

”1:

59

1: 1

191:

178

1: 2

381:

357

1: 4

751:

535

1: 4

871:

496

1: 5

581:

106

91:

130

71:

190

11:

237

61:

285

21:

356

4

0.25

”1:

34

1: 6

81:

102

1: 1

361:

204

1: 2

721:

306

1: 2

821:

304

1: 3

441:

612

1: 7

481:

108

81:

136

01:

163

21:

204

0

Spiral Plug Length

#8

-32

MET

ERIN

G T

IPS

Flow

Rat

e(G

PM) a

t 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

Inje

ctor

Col

orW

hite

Yello

wTa

nRe

dO

rang

eG

ray

Blue

Ligh

t Bl

ueLi

ght

Gre

enPi

nkPu

rple

Dar

k G

reen

Blac

kBl

ack

Blac

kBl

ack

CO

PPER

1: 5

71:

104

1: 1

551:

195

1: 2

811:

406

1: 4

681:

598

1: 6

291:

739

1: 8

811:

107

41:

201

91:

231

81:

332

41:

425

9

PUM

PKIN

1: 4

31:

82

1: 1

191:

126

1: 2

381:

348

1: 3

981:

519

1: 5

541:

647

1: 7

741:

946

1: 1

465

1: 1

832

1: 2

310

1: 3

042

BURG

UN

DY

1: 3

41:

67

1: 9

71:

111

1: 2

071:

304

1: 3

471:

461

1: 4

951:

575

1: 6

901:

845

1: 1

244

1: 1

670

1: 1

975

1: 2

469

LIM

E1:

28

1: 5

71:

81

1: 1

001:

183

1: 2

701:

307

1: 4

141:

447

1: 5

181:

622

1: 7

641:

988

1: 1

262

1: 1

481

1: 1

958

TAN

1: 2

81:

57

1: 8

11:

100

1: 1

831:

270

1: 3

071:

414

1: 4

471:

518

1: 6

221:

764

1: 8

261:

104

21:

128

61:

155

7

ORA

NG

E1:

23

1: 4

41:

64

1: 7

81:

137

1: 1

961:

215

1: 2

931:

314

1: 3

651:

437

1: 5

361:

751

1: 8

741:

113

61:

126

2

TURQ

UO

ISE

1: 1

71:

31

1: 4

51:

55

1: 9

11:

126

1: 1

341:

185

1: 1

971:

230

1: 2

741:

336

1: 5

611:

752

1: 8

851:

109

9

PIN

K1:

14

1: 2

41:

35

1: 4

21:

68

1: 9

31:

98

1: 1

301:

143

1: 1

591:

188

1: 2

241:

372

1: 4

731:

570

1: 7

28

LIG

HT

BLU

E1:

11

1: 1

71:

24

1: 3

11:

47

1: 6

41:

66

1: 9

31:

98

1: 1

141:

136

1: 1

661:

318

1: 4

061:

483

1: 5

72

BRO

WN

1: 1

01:

15

1: 2

21:

28

1: 4

31:

58

1: 5

91:

84

1: 8

81:

103

1: 1

221:

150

1: 2

701:

338

1: 4

081:

507

RED

1: 1

21:

17

1: 2

31:

34

1: 4

51:

46

1: 6

51:

69

1: 8

01:

95

1: 1

161:

202

1: 2

541:

306

1: 3

75

WH

ITE

1: 1

21:

16

1: 2

21:

31

1: 4

21:

43

1: 6

11:

64

1: 7

41:

88

1: 1

081:

180

1: 2

261:

272

1: 3

43

GRE

EN1:

11

1: 1

41:

20

1: 2

81:

37

1: 3

81:

53

1: 5

51:

65

1: 7

61:

94

1: 1

601:

201

1: 2

411:

300

BLU

E1:

10

1: 1

21:

17

1: 2

31:

30

1: 3

11:

44

1: 4

61:

53

1: 6

31:

77

1: 1

221:

152

1: 1

851:

224

YELL

OW

1: 9

1: 1

21:

16

1: 2

01:

22

1: 3

01:

31

1: 3

61:

42

1: 5

21:

80

1: 1

001:

120

1: 1

48

BLA

CK

1: 1

01:

13

1: 1

61:

17

1: 2

31:

24

1: 2

81:

33

1: 4

01:

61

1: 7

71:

92

1: 1

15

PURP

LE1:

6.6

1: 8

.31:

91:

10

1: 1

31:

13

1: 1

51:

17

1: 2

11:

31

1: 3

91:

46

1: 5

7

GRA

Y1:

5.3

1: 6

.71:

6.9

1: 7

.61:

9.9

1: 1

01:

11.

61:

13

1: 1

61:

24

1: 3

01:

35

1: 4

4

OPE

N1:

4.9

1: 5

.31:

5.2

1: 6

.01:

6.1

1: 6

.11:

7.6

1: 8

.31:

10

1: 1

21:

15

1: 1

81:

23

Metering TipNO

TE: D

iluti

on

rati

os

giv

en a

re b

ased

on

dra

win

g w

ater

thr

oug

h th

e m

eter

ing

tip

s an

d a

re m

eant

as

a st

arti

ng p

oin

t fo

r sy

stem

co

nfig

urat

ion.

R

esul

ts a

re e

xpec

ted

to

var

y w

hen

dra

win

g c

hem

ical

s d

ue t

o d

iffer

ence

s in

vis

cosi

ty a

nd t

emp

erat

ure.

The

re m

ay b

e sl

ight

var

iati

ons

of

per

form

ance

in

inje

cto

rs a

nd m

eter

ing

tip

s th

at a

re u

navo

idab

le d

ue t

o m

anuf

actu

re t

ole

ranc

es. U

sing

the

sam

e ti

p c

olo

r fr

om

sit

e to

sit

e is

a g

oo

d s

tart

ing

po

int.

H

ow

ever

, wit

h th

e p

ote

ntia

l fo

r va

riat

ion

fro

m p

art,

to

par

t it

is r

easo

nab

le t

o s

till

need

to

do

so

me

adju

stm

ents

fro

m t

here

.

3/8”

po

lyflo

w (L

LDP

E) t

ubin

g is

req

uire

d t

o e

nsur

e a

seal

bet

wee

n th

e tu

be

wal

l and

the

sp

iral

plu

g.

(Ass

umes

feed

pre

ssur

e of

200

PSI

(14

bar)

)


RECOMMENDED SETUP STARTING POINTS

FoamingAir:Startat25PSI(adjustbasedonuniqueapplication)

Foroptimalperformance,matchtheflowoftheinjectortotheflowofthenozzlesorapplicator.Thismayinvolvechangingnozzlesand/orremovingorpluggingsomeports.Seebelowforrecommendedsetupstartingpoints.

APPLICATOR INJECTOR(S) PART NUMBER/COLORScentDispenser (1.0 GPM) (3.8 LPM)

CTANozzles(ForShowerhead,SeeBelow) (1.0 GPM) (3.8 LPM)

FoamStick (1.5 GPM) (5.7 LPM)

Mitter/WrapNozzles (1.5 GPM) (5.7 LPM)

Undercarriage/RustInhibitor (2.0 GPM) (7.6 LPM)

VJetOrFlatFanNozzleArch (2.25 GPM) (8.5 LPM)

K12NozzleArch (2.25 GPM) (8.5 LPM)

K15NozzleArch (3.25 GPM) (12.3 LPM)

HockeyPuck1 Row Of Holes

(0.75 GPM) (2.8 LPM)2 Rows Of Holes


(1.5 GPM) (5.7 LPM)

Showerhead1 Row Of Holes



(2.0 GPM) (7.6 LPM)

RainBar1 Row Of Holes



(5.5 GPM) (20.8 LPM)

LowFlowFoamCurtain-ChooseFoamAccessoryBasedOn#OfInputs/FoamGenerators

Duo-Foam With (2X)(3.25 GPM) (12.3 LPM)

Triple-Foam With (3X)(2.25 GPM) (8.5 LPM)

HighFlowFoamCurtainApplication-WorksWithUpTo4Inputs/FoamGenerators

(8.0 GPM) (8.5 LPM) With Distribution Manifold

(XD Gen2, HD)


(XD Gen2, HD)


(XD Gen2, HD)


Max Pressure Inlet / Outlet Up to 250 PSI (17 bar)

Temperature Range 33°F - 140°F (.5°C - 60°C)

Maximum Wrench Torque (PC2) Hand Tighten Only (30 in-lbs)

Maximum Wrench Torque (PC3) Hand Tighten Only (60 in-lbs)

INLET CONNECTION PC2* PC3*

OUTLET CONNECTION 3/8” MNPT 3/4” MNPT

FOR USE WITH AQUA-LAB MODEL(S) MD GEN2, XD GEN2, HD XD GEN2, HD

COLOR FLOW RATE @ 200 PSI (14 bar)

SINGLE BARB

DUAL BARB SINGLE BARB

White 0.25 GPM (1.0 LPM) 718029 - -

Yellow 0.50 GPM (1.9 LPM) 718040 729040 -

Tan 0.75 GPM (2.8 LPM) 718051 729051 -

Red 1.00 GPM (3.8 LPM) 718057 729057 -

Orange 1.50 GPM (5.7 LPM) 718070 729070 -

Gray 2.00 GPM (7.6 LPM) 718083 729083 -

Dark Blue 2.25 GPM (8.5 LPM) 718086 729086 -

Light Blue 3.00 GPM (11.3 LPM) 718095 729095 -

Light Green 3.25 GPM (12.3 LPM) 718098 729098 -

Pink 3.75 GPM (14.2 LPM) 718106 729106 -

Purple 4.50 GPM (17.0 LPM) 718117 729117 -

Dark Green 5.50 GPM (20.8 LPM) 718125 729125 -

Black 8.00 GPM (30.3 LPM) - - 818161

Black 10.0 GPM (37.9 LPM) - - 818177

Black 12.0 GPM (45.2 LPM) - - 818186

Black 15.0 GPM (56.8 LPM) - - 818207

SPECIFICATIONS

*For exclusive use with Aqua-Lab Chemical Dispensing Systems.

COMPOSITE CHEM-FLEX INJECTOR PART NUMBERS


PRESSURE LOSS IN RUN LENGTH

All solution line tubing should be selected for 10 PSI or less of pressure loss.*20 PSI pressure loss may be acceptable depending upon nozzle sizing, foamers, check valves and other line restrictions present in application.All numbers represent pressure loss in PSI for selected solution line tubing.

GREEN = GOOD YELLOW= USE CAUTION RED = NOT RECOMMENDED

INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.00 3.25 3.75 4.50 5.50

Injector Color White Yellow Tan Red Orange Gray Blue Light Blue Light Green Pink Purple Dark Green150’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 6 PSI 7 PSI 9 PSI 13 PSI* 18 PSI*125’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 8 PSI 11 PSI* 16 PSI*100’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 9 PSI 13 PSI*75’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 3 PSI 4 PSI 5 PSI 7 PSI 9 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 3 PSI 5 PSI 6 PSI25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI

Run

Leng

th

5/8” ID BRAIDED

INJECTORFlow Rate (GPM) at 200 PSI 8.0 10.0 12.0 15.0

Injector Color Black Black Black Black100’ 10 PSI 15 PSI* 21 PSI 32 PSI75’ 8 PSI 11 PSI* 16 PSI* 24 PSI50’ 5 PSI 8 PSI 11 PSI* 16 PSI*25’ 3 PSI 4 PSI 6 PSI 8 PSIRu

n Le

ngth

3/4” ID BRAIDEDINJECTOR

Flow Rate (GPM) at 200 PSI 8.0 10.0 12.0 15.0

Injector Color Black Black Black Black100’ 3 PSI 4 PSI 5 PSI 8 PSI75’ 2 PSI 3 PSI 4 PSI 6 PSI50’ 1 PSI 1 PSI 3 PSI 4 PSI25’ 1 PSI 1 PSI 2 PSI 2 PSIRu

n Le

ngth

1” ID BRAIDED


Injector Color White Yellow Tan Red Orange Gray Blue Light Blue Light Green Pink Purple Dark Green150’ 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 9 PSI 11 PSI 18 PSI* 21 PSI 27 PSI 36 PSI 56 PSI125’ 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 8 PSI 9 PSI 15 PSI* 18 PSI* 23 PSI 30 PSI 47 PSI100’ 1 PSI 1 PSI 2 PSI 2 PSI 4 PSI 7 PSI 8 PSI 12 PSI* 14 PSI* 18 PSI* 24 PSI 36 PSI75’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 6 PSI 9 PSI 11 PSI* 14 PSI* 18 PSI* 26 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 4 PSI 4 PSI 6 PSI 8 PSI 9 PSI 12 PSI* 18 PSI*25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI 5 PSI 3 PSI 9 PSI

Run

Leng

th

1/2” ID BRAIDED


Injector Color White Yellow Tan Red Orange Gray Blue Light Blue Light Green Pink Purple Dark Green150’ 1 PSI 5 PSI 7 PSI 11 PSI* 22 PSI 36 PSI 44 PSI 76 PSI 88 PSI 115 PSI 154 PSI 239 PSI125’ 1 PSI 4 PSI 6 PSI 9 PSI 18 PSI* 30 PSI 37 PSI 63 PSI 73 PSI 101 PSI 129 PSI 200 PSI100’ 1 PSI 3 PSI 5 PSI 7 PSI 14 PSI* 23 PSI 28 PSI 50 PSI 54 PSI 77 PSI 103 PSI 142 PSI75’ 1 PSI 2 PSI 4 PSI 6 PSI 12 PSI* 18 PSI* 22 PSI 37 PSI 42 PSI 53 PSI 77 PSI 106 PSI50’ 1 PSI 1 PSI 3 PSI 4 PSI 8 PSI 12 PSI* 15 PSI* 25 PSI* 28 PSI 39 PSI 52 PSI 73 PSI25’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 7 PSI 12 PSI* 13 PSI* 19 PSI* 26 PSI 34 PSI

Run

Leng

th

3/8” ID, 1/2” OD POLY TUBE


FACTORY LIMITEDHydra-Flex,Incwarrantsitsequipmenttobefreefromdefectinmaterialorworkmanshipunderproper

normaluseforaperiodofone(1)yearbeginningthedateofpurchase.

Hydra-Flex,Inc’sliabilityshallbelimitedtorepairorreplacementofpartsfoundtobedefectivewithinthe

warrantyperiodandfollowingHydra-Flex,Inc’sinspection.Hydra-Flex,Incshallhavetheoptionrequiring

thereturnofdefectivematerialtoestablishthepurchaser’sclaim.Intheeventofrepairorreplacement

thislimitedwarrantyisnon-cumulative.Neitherlabornortransportationchargesareincludedinthis

warranty.

Thiswarrantyisbaseduponthepropercareandmaintenanceofthewarrantedequipment.Warranty

doesnotapplyifthemerchandiseisalteredormodifiedinanyway.Warrantydoesnotapplytoany

equipmentwhichhasbeensubjecttomisuse,inappropriateuseoftools,includingexposuretoharsh

chemicals,neglect,lackofmaintenance,freezing,fluidhammer,accident,thirdpartydamage,fluid

impuritiessuchassandorminerals,actsofGodoractsofwar.Nordoesitapplytoanyequipmentwhich

hasbeenrepairedoralteredbyanyonenotsoauthorizedbyHydra-Flex,Inc.Allequipmentmustbe

properlyinstalledinaccordancewithspecifiedplumbing,electrical,andmechanicalrequirements.The

warrantydoesnotapplytonormalwearandtearorroutinemaintenancecomponentsasdescribedinthe

equipmentmanual.

Exceptasexpresslystatedherein,Hydra-Flex,Incshallnotbeliablefordamagesofanykindin

connectionwiththepurchase,maintenance,oruseofthisequipmentincludinglossofprofitsandall

claimsforconsequentialdamages.Thislimitedwarrantyisinlieuofallotherwarrantiesexpressedor

implied.Hydra-Flex,Incneitherassumesnorauthorizesanypersontoassumeforitanyotherobligation

orliabilityinconnectionherewith.Thiswarrantyisneitherassignablenortransferable.

Transportationdamageclaimsaretobesubmittedtothecarrierofthedamagedmaterial.

AQUA-LAB HD/XD™ WARRANTY


11

13

13

132

2

33

55

1717 15

15

14

28

28

28

4

4

6

6

12

12

12

16

23

23or24

23or24

9

9

9

8

8

8

7

7

710

10

10

11

11

11

18

AQUA-LAB™ - PANEL PARTS DIAGRAM & LIST


NUMBER PART NAME PART NUMBER1 Single MAM Valve Replacement 1002505

2 Single BAM Valve Replacement 1002216

3 MAM Valve Repair Kit 1002752

4 BAM Valve Repair Kit 1002223

5 MAM O-Ring Repair Kit 1002751

6 BAM O-Ring Repair Kit 1002222

7 Solenoid Actuated Air Valve - Foaming

24VAC - 1001428

24VDC - 1001429

120VAC - 1001430

8 Solenoid Coil Replacement For Air Actuated Valve

24 VAC - 1002855

24 VDC - 1002856

120 VAC - 1002857

9 M12 X Din I Cordset24 VAC/VDC - 3001957

120 VAC - 3001958

10 Primary Air Regulator 1001184

11 Primary Air Regulator Replacement Bowl 1002861

12 Foaming Small Air Regulator & 60 PSI Gauge 1002872

13 Outlet Pressure Gauge 0-400 PSI Bottom Mount 3000491

14 MAM Inlet Kit 1002508

15 BAM Inlet Kit 1002396

16 BAM To MAM Coupler 1002538

17 MAM End Cap Kit 1002507

18 BAM End Cap Kit 1002395

19 1/4” Push To Connect Tee 3000815

20 1/4” Push To Connect To 1/8” NPT Elbow 3000803

21 1/4” Push To Connect To 1/8” NPT Elbow - Plastic 3002033

22 1/4” Hose Barb Foaming Air Check Valve 3000819

23 M12 Junction Block - 8 Port, With Homerun Cable30’ (10 m) - 1002875

100’ (30 m) - 1002876

24 M12 Junction Block - 6 Port, With Homerun Cable30’ (10 m) - 1002877

100’ (30 m) - 1002878

25 Ball Valve1” - 3000509

1/2” - 3000565

26 Manifold Inlet 3/4” ID Hose X 1/2” NPT Ends - 72” (1.8 m) Long 3000579

27 Manifold Inlet 1” ID Hose X 1” NPT Ends - 72” (1.8 m) Long 3001732

28 Male Quick Connect - Brass1” - 3000205

1/2” - 3000500

29 Female Quick Connect - Brass1” - 3000206

1/2” - 3000502

All panel replacement parts found on Hydra-Flex website.


34 39

38

37

32

42

29

40

40

28

28

29

29

30

30

31 or 32

35

35

36

33

All Pump replacement parts found on Hydra-Flex website.

AQUA-LAB™ - PUMP PARTS DIAGRAM

29

29

43


NUMBER PART NAME PART NUMBER

28 Male Quick Connect - Brass1” - 3000205

1/2” - 3000500

29 Female Quick Connect - Brass1” - 3000206

1/2” - 3000502

30 1” Wye Strainer - 30 Mesh 3000490

31 1” NPT T16 Wye Strainer Screen & Gasket Kit 1001938

32 1” NPT T15 Wye Strainer Screen & Gasket Kit 1001939

33 40 GPM (150 LPM) Bypass Pressure Regulator - Stainless Steel 3000464

34 Quick Connect 9’ (3 m) Cordset For Booster Pump 3000782

35 Temperature Switch Assembly 3000507

36 20 GPM (75 LPM) Quick Connect Regulator Plumbing Assembly 1002340

37 40 GPM (150 LPM) Grundfos Plumbing Assembly 1002130

38 Grundfos Pump System Manifold O-Ring 3001878

39 Replacement/Backup 40 GPM (150 LPM) Grundfos Pump 3001618

40 Replacement/Backup 20 GPM (75 LPM) Booster Pump 1001362

41 (Not Shown) Booster Pump Floor Stand 1002250

42Dual Booster Pump Wall Mount Bracket 3000921

Triple Booster Pump Wall Mount Bracket 3000950

43 VFD MCU Pressure Transducer 3001705

AQUA-LAB™ - CONTROL PARTS LIST


49 or 50

49 or 50

45

45

68

48 46

46

47

47

56

56

66

66

60

61

62

63

64

49or50

49or50

59

54

67

51or52

55

AQUA-LAB™ - CONTROL PARTS DIAGRAM

MCU WITH SMART RELAY

MCU WITH OUT SMART RELAY


AQUA-LAB™ - CONTROL PARTS LIST

All motor control unit replacement parts found on Hydra-Flex website.

NUMBER PART NAME PART NUMBER44 (Not Shown) M12 Cordset (Gray) 3000347

45 High-Temp Light 3002512

46 Quick Connect Pump Plug - Female 3000783

47 Thermal Overload - Eaton 1002757

48 Timer Relay 1002758

49 Current Sensor - AC 3000666

50 Current Sensor - DC 3000866

51 (Grundfos) VFD Replacement - 5HP230V - 1002664

480V - 1002666

52 (Grundfos) VFD Replacement - 7.5HP230V - 1002665

480V - 1002667

53 (Not Shown) (Grundfos) VFD MCU Keypad 3002373

54 (Grundfos) VFD MCU Exhaust Fan 3001869

55 (Grundfos) VFD MCU Exhaust Filter 3001868

56 Contactor - Eaton

24 VAC - 3001336

24 VDC - 3001337

120 VAC - 3001338

57 (Not Shown) VFD MCU Pressure Transducer 3001705

58 (Not Shown) Pressure Transducer Cable 3001867

59 (Grundfos) VFD MCU Primary Fuse 1/2 AMP 3001870

60 (Grundfos) VFD MCU Fuse30A - 3001871

60A - 3001872

61 20 GPM (Booster Pump) VFD Replacement230V - 1002926

460V - 1002927

62 Power Supply230V - 1002924

460V - 1002925

63 Relay Socket 1002928

64 20 GPM (Booster Pump) VFD Disconnect Switch & Handle Replacement Kit 1002930

65 (Not Shown) 20 GPM (Booster Pump) VFD MCU Key Pad Replacement 3002589

66 MCU Disconnect Switch & Handle Replacement 1002885

67 VFD Disconnect Switch & Handle Replacement230V - 1002845

460V - 1002844

68 Smart Relay

24 VAC - 1002894

24 VDC - 1002895

120 VAC - 1002896


1. TROUBLE SHOOTING VFD FOR GRUNDFOS

FAULT TYPE POTENTIAL FAULT CAUSES

0001 – Overcurrent (Motor current draw than expected)

Motorproblem

Accel/Deceltimestoolow

Lowincomingvoltage(Especially208V)

0002 – DC overvolt VFDBad,needtoreplace

0009 – Motor Over Temp Seeresolutionsforcodes2010and0001

0022 – Supply Phase Lostincomingpowerphase-Checkbreaker&powersupply

0042 - Low Inlet Pressure

Reverserotation

Restrictionininletline

Inlocalmode,switchtoremotemode

Badpressuretransducerorpoorwiringconnectiontotransducer

2010 – Motor Temp (calculated based on speed and current)

Likelymotorrunningbackwards-reverserotation

Alsoseeresolutionsforcodes0009,0001

PROBLEM PROBLEM CAUSESPower fuses are blown Hooked480Vto230VVFD,returntoHFI,VFDisalsonowBAD

Surging gauge pressure CallHFI,canberelatedtohighpressurehoselength

Disconnect switch breakage Improperdooropeningprocedure,replaceparts

Common Fault Code

Common Problems

2. TROUBLE SHOOTING MCU WITH HIGH TEMP SHUTDOWN

PROBLEM PROBLEM CAUSESGrey cable CrossthreadingonM12connector,screwnotengagedfarenough

Bad timer relayReplace,canbecausedbybackfeedingpoweronneutralwire

TimerrelayshouldbesettoT-6secondsandModesetto“R”.Cyclepowertoresettimerforchangestotakeeffect.

Bad current switch Lowvoltagetovalves,notenoughwirewrapsoncurrentswitch,wrongvoltageformotorcontrolunit

Doesn’t start motor ConstanthotorneutralonCWC(CarWashController)burnedout

Motor won’t run or runs continuous Contactorstuckon,replacewithnew15ampcontactor(orlostphase)check

Red (High-Temp) light won’t go off

Wiretotempswitchnotconnected

Poorcrimponwirestotempswitchatconnector

Constanthotconnectionsatcarwashcontrollerarebad

NoconstanthotorE-STOPtomotorcontrolunit

Hotwatertoinlet>110°F

Excessiverecirculationduetoincorrecttimerrelaymodesetting(setto“R”at6seconds)

Excessiverecirculationduetotoosmallinjector(1GPMtotalflowrequired)

Excessiverecirculationduetoleakingbugprepgun,callHydra-Flex

Excessiverecirculationduetobadbugprepsystem,alkalinecoagulationorleakingofcustomersuppliedbugprepline

Common Problems


3. LIGHT IDENTIFICATION

PROBLEM CAUSESGreen Illuminated SupplyvoltageappliedtotimerfromMCC(MainCarwashController)

Yellow Illuminated Relayclosed,contactorshouldbeclosed

Green Flashing Timerstarted(Dialshouldbesetto“R”foroffdelaytimer),pumpshouldshutoffin6seconds

PROBLEM CAUSESLED Off Noamps,outputopen,pumpshouldbeofforturnoffin6seconds

LED Red Ampsabovetriplevel,outputclosed,pumpshouldberunning

The Eaton TRL04 Timer

Current sensor new with eaton relay (black Dwyer box)

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

4000129 revK0119

CHEMICAL DISPENSING SYSTEM · PANEL 1. Drill 3/8” holes in wall for bottom slots (20” on center...

Documents

Transcript of CHEMICAL DISPENSING SYSTEM · PANEL 1. Drill 3/8” holes in wall for bottom slots (20” on center...