CHEMICAL DISPENSING SYSTEM - Hydra-Flex Inc
Transcript of CHEMICAL DISPENSING SYSTEM - Hydra-Flex Inc
© Hydra-Flex, Inc. 2017
AQUA-LAB SD™CHEMICAL DISPENSING SYSTEM
User ManualREV G
4000061 revG0518© Hydra-Flex, Inc. 2018
© Hydra-Flex, Inc. 2018
TABLE OF CONTENTS
Specifications 1
Aqua-LabSDSystemDiagrams 2
LayoutDrawing 4
EstimatedInstallationTimeline 5
InstallationInstructions 5
InitialInjectorSetup 8
OptimizingTheSystem 8
NozzleSetup 9
ChemicalUsageMeasurement 10
RecommendedMaintenance 10
AirOperatedValveReplacement 11
Troubleshooting 11PumpIssues 11InjectorIssues 12PressureRegulatorIssues 12Flow/Archissues 12ValveIssues 12
InjectorOptimizationTool 13
Appendix 14Chem-FlexInjectorDilutionRatioChart 14Chem-FlexInjectorPartNumbers 15PressureLossInRunLength 16WiringDiagram 17Startup 18PumpCurves 19ReplacementParts 20Accessories 23Aqua-LabWarranty 24
© Hydra-Flex, Inc. 2017
SPECIFICATIONS
AIR-ACTUATED VALVES
24 VAC or 24 VDC or 120 VAC, 3.5 Watts Per Port
PUMPS
20 GPM @ 200 PSI (Assuming at least 30 PSI city feed)*
208-230V/3PH/8.9A or 460V/3PH/4.1A or 575V/3PH/4.1A
10 GPM @ 200 PSI (Assuming at least 30 PSI city feed)*
208-230V/3PH/7.4A or 460V/3PH/3.7A or 575V/3PH/3.7A
POWER REQUIREMENTS(IF PUMP WAS PURCHASED FROM HYDRA-FLEX)
DIMENSIONS (W x H)IF PUMP & MOTOR CONTROL UNIT WAS PURCHASED FROM HYDRA-FLEX
MOTOR CONTROL UNIT
Single / Dual
14”w x 15”h
PANELS
SD
22”w x 17”h
PUMP ASSEMBLIES
1-Pump
24”x 48”
AIR SUPPLY CONFIGURATIONAir Inlet Line 3/8” OD Polyflow Per SD Panel
Air Inlet Pressure 80-120 PSI Dry Air
Aqua-Lab SD4 4 Hydra-Cannons
Aqua-Lab SD5 5 Hydra-Cannons
Aqua-Lab SD6 6 Hydra-Cannons
Aqua-Lab SD7 7 Hydra-Cannons
Aqua-Lab SD8 8 Hydra-Cannons
WATER SUPPLY(IF PUMP WAS PURCHASED FROM HYDRA-FLEX)
Water Inlet Lines20 GPM 10 GPM
1” ID 1” ID
Operating Water Pressure 200 PSI (Factory Set) Assuming 40 PSI City Feed
Maximum Water Source Temperature Recommended 110˚F (43˚C)137˚F (58°C) with Booster Pump
Water Filtration (Suggested) 50 Micron
FOR ADDITIONAL SUPPORT CALL
952-808-3640OR VISIT US ON THE WEB:
www.hydraflexinc.comPage | 1
*See page 19 for pump curves.
© Hydra-Flex, Inc. 2018 Page | 2
AQUA-LAB SD SYSTEM DIAGRAMS(AQUA-LAB SD6 SHOWN)
Air Pilot Valve
Air Inlet Port Black
FOR PART NUMBERS & DIAGRAMS - SEE PAGES 20-22
Hydra-Cannon Manifold
Primary Water Connection
Solution Ports
Air Actuated Hydra-Cannon Valve
1 42 53 6
Mounting Slots (2 top, 2 Bottom)17.5”
Timer Relay
Contactor
Thermal Overload
Current Switch3 Phase Disconnect
Quick Connect Pump Plug Female
Grey M12 Cables (Carry signal from yellow M12 distribution block to motor starter that turns on the pump)
EATON
OPTIONAL MOTOR STARTER
Temperature Shutdown
Relay
Timer Relay
Contactor
Thermal OverloadCurrent Switch3 Phase Disconnect
Quick Connect Pump Plug Female
Grey M12 Cables (Carry signal from yellow M12 distribution block to motor starter that turns on the pump)
SPRECHER & SCHUH
© Hydra-Flex, Inc. 2017 Page | 3
PUMP DIAGRAM(SINGLE SOURCE / SINGLE PUMP SHOWN)
Inlet Ball Valve(Optional)
20 GPM Bypass Pressure Regulator
Thermal Relief Valve - 1/2” NPT
Wye Strainer
Quick Connect 9’ Cordset For Pump (Plugs Into Bottom Of Motor Starter)
FOR PART NUMBERS & DIAGRAMS - SEE PAGE 21
20 GPM PUMP
10 GPM PUMP
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)
© Hydra-Flex, Inc. 2018
50.5”
7”
LAYOUT DRAWING
Page | 4
Optional Hydra-Flex Motor Starter/Pumps
20 GPM Pump
10 GPM Pump
13.00
15.50
21.89
16.89
23.88
46.02
© Hydra-Flex, Inc. 2017
10 GPM Pump
Page | 5
WHO TASK EST. TIME
DISTRIBUTOR MONITOR & RECORD PERFORMANCE 2HR/WK
DISTRIBUTOR MAINTENANCEPERSCHEDULEORASNEEDED
POST INSTALLATION
TOTAL HOURS SPENT
INSTALLATION
TOTAL CUSTOMER 1 HR
TOTAL DISTRIBUTOR/TECHNICIAN 11 HR
TOTAL PLUMBER (OPTIONAL) 4 HR
PRE-INSTALLATION
ESTIMATED INSTALLATION TIMELINE
WHO TASK EST. TIME
DISTRIBUTOR&CUSTOMER DETERMINELOCATIONTOINSTALLEQUIPMENT 1 HR
PLUMBER INSTALLWATERSUPPLYLINE(IFUSINGOPTIONALHYDRA-FLEXPUMP) 4 HR
TECHNICIAN LABEL ALL CONTROLLER RELAYS AT CONTROLLER .5 HR
TECHNICIAN RUNSOLUTIONLINES 2 HR
TECHNICIAN INSTALLAIRSUPPLYLINE .5 HR
TOTAL LABOR HOURS 8 HRS
WHO TASK EST. TIME
DISTRIBUTOR/TECHNICIAN HANGEQUIPMENT 1 HR
TECHNICIAN CONNECTWATER,AIRANDSOLUTIONLINES 1 HR
TECHNICIAN CONNECTCONTROLLEADSTOMAINCONTROLLERORJUNCTIONBOX 2 HR
DISTRIBUTOR/TECHNICIAN STARTUP(INJECTOR,METERINGTIPANDNOZZLESELECTION) 3HR
DISTRIBUTOR/TECHNICIAN DOCUMENTCONFIGURATION 1 HR
TOTAL LABOR HOURS 8 HRS
***Installation takes approximately one day. An electrician and a plumber are needed for half a day.
General Skill Level• Mechanical:Basic-mountingequipment• (Optional)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:• AmpMeter
• VoltMeter
© Hydra-Flex, Inc. 2018 Page | 6
UNPACKINGTheAQUA-LABSDisshippedinaboxorinacrateforprotectionifoptional pumpisorderedwithit.
***Be sure not to discard the manuals and accessories box.
LOCATION & MOUNTING**IflocationwasnotidentifiedduringthePre-InstallationProcess,makesuretoconsidertheproximitytofeedwater,powersupply,andthecontrolcabinetas wellasspacenearthesystemtostorechemicalcontainers.
***See drawing in reference for general layout
AQUA-LAB SD1. Drill(4)5/32”holesonthewall.17.50”wide,14.89”tall.
2. PressSDboardtightagainstthewall.
3. Screwin3/16”concretescrewswithawasher.
(OPTIONAL HYDRA-FLEX) 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.
(OPTIONAL HYDRA-FLEX) MOTOR STARTER1. Mounttothewallwith4appropriateanchors.
2. Screwin3/16”concretescrewswithawasher.
(OPTIONAL) FEED WATER CONNECTION (IF USING HYDRA-FLEX PUMP 7.5 GPM)**PRIOR TO CONNECTION, ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES
• Connectpre-runmainwatersupplylinetopumpinletwithhosesupplied.
200 PSI FEED WATER CONNECTION (IF USING EXISTING PUMP)**PRIOR TO CONNECTION, ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES
• Connectsupplyfromregulatedpumptomalequickconnectfitting asshown.
PNEUMATIC CONNECTIONS• Connectpre-run3/8”ODpolyfeedlinetopushconnectfitting.
© Hydra-Flex, Inc. 2017 Page | 7
******************(HFI supplied motor starter)******************
1. ELECTRICAL CONNECTIONS (HFI MOTOR STARTER)a. Wire yellow homerun control cables to car wash control panel from optional M12 junction block. (See diagram below for wiring schematic)
• 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.
ELECTRICAL CONNECTIONS (NO HFI MOTOR STARTER)Single Power Connection
a. Select from the option below that fits the version you purchased.
• Air Pilot Valves• Connect your signal wires to the terminals on the air solenoids
• Pin 1 = Ground• Pin 2 = Positive• Pin 3 = Negative• Pin 4 = Ground
• Air pilot valves with field wires1. Connect the first black wire to Positive2. Connect the other black wire to Negative3. Connect the green wire to Ground
b. Remove the cap from port 6 then, connect the grey M12 cables hanging out of the motor starter box to the NEUTRAL/COMMON port 6 of the yellow M12 junction boxes.
i. If you have more panels than gray wires from the motor starter box, 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 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.
1
12
3
4
5
3
12
3
4
5
5
12
3
4
5
2
12
3
4
5
4
12
3
4
5
6
12
3
4
5
Ground: Green/yellow
Do Not Use - Blue (Cap With Wire Nut)
Neutral / Common: Red
Hydra-Cannon Port 1: White
Hydra-Cannon Port 2: Green
To Motor Starter Box
Hydra-Cannon Port 3: Yellow
Hydra-Cannon Port 4: Grey
Hydra-Cannon Port 5: Pink
Control Voltage Constant Hot / + Brown
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!).
(Left to right on water manifold, top to bottom on air valves refer to diagram on page 2)
© Hydra-Flex, Inc. 2018 Page | 8
(Based on field experience this is Hydra-Flex’s recommended starting point)1. Usingtherecommendedstartingpoint(Page15)orthetargetflowrateandthechemicaldilutions
chart(appendixPage14)installtheappropriateinjectorintoeachport.
2. Connectpre-runsolutionlinestoeachinjectorwiththesuppliedcheckvalveandpushconnectfitting.
a. Be sure to use Teflon tape when connecting the injector to the check valve and push connect fitting to ensure there are no leaks. b. Do not over tighten poly fittings or they may crack (HAND TIGHTEN ONLY).
3. Connectpolylinesfromeachchemicalcontainertothehosebarbontheappropriateinjector.
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(seeappendixPage14forratiochartsto determinetip.)
INITIAL INJECTOR SETUP
What do metering tips do?• Increasesordecreasestheamountof
chemicalinthesolution.
What do nozzles do?• Determinesthepatternandbackpressure
ofthesolution.
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.
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)
© Hydra-Flex, Inc. 2017 Page | 9
(Optional For Maximized Optimization)• Usingtherecommendedstartingpoint(appendix)installtherecommendednozzles.
• Thismayinvolveremovingandpluggingsomeports.• DuetothelowerwaterusagedeterminedbytheinjectoroftheAQUA-LAByouwillneedto
matchtheflowoftheapplicationdevicetotheinjector.• Setupthenozzlespraypatternsto“paint”thecar-slightlyoverlappingeachother.
NOZZLE SETUP
• Too much chemical used• Decrease metering tip• Decrease metering tip and injector
size (to maintain desired ratio)
• No chemical • Check vacuum/backpressure of
injector for clogging (see page 13 for Injector Optimization Instructions or pages 12 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)
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 2
2.25 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 5IN
JECT
OR
FLO
W R
ATE
@ 2
00 P
SI (G
PM)
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 19IN
JECT
OR
FLO
W R
ATE
@ 2
00 P
SI (G
PM)
© Hydra-Flex, Inc. 2018 Page | 10
CHEMICAL USAGE MEASURINGVERIFY TITRATION OF CHEMICALS BEFORE PROCEEDING1. Setuplabscalewithsmallbucketofchemicaltobe
measured.
2. Putthesuctionlineintothebucket.
3. Runtheapplicationbeingtestedto“prime”theline.(Allairbubblesmustberemovedforaccuracy.)
4. RecordtheInitial Weight fromthescale.(Tarringthescalewithweightonthescalecanaffectaccuracy.)
5. Runtheapplicationfor1vehicle(ormanuallyforthesameamountoftimeitwouldbeonfor1vehicle).
6. RecordtheFinal Weightfromthescale.7. SubtracttheInitialWeightfromtheFinalWeightto
determinetheweightofusedproduct.
8. DividethePer Car Weightingramsbythespecificgravityofthechemicaltodeterminethemillilitersofchemicalusedpervehicle.
9. Repeatforeachchemicalapplication.
0
8
16
24
Line Length (See Page 16 For Proper Line Sizing)• Longerlinesaddbackpressureduetotheinherentresistancecausedbyfriction.Seeifyoucan
reducethelinelengthorincreasetheinsidediameter.
RECOMMENDED MAINTENANCETHE RECOMMENDED SERVICE AND MAINTENANCE ON THE AQUA-LAB SYSTEM ARE AS FOLLOWS. Monthly
• Checkwaterfilterandreplaceasneeded(ifinstalled).• Checkandcleanwyestrainer(IfusingtheoptionalHydra-Flexpump).
Semi-Annually• Checkandreplaceinjectormeteringtips.• Inspectandreplacechemicallinesasneeded.• Ensurelinesaretightlysecuredtoinjectorhosebarbs,clip1”offoldhoseasneededthatwas
stretchedbyhosebarb.
Annually• Cleanwaterregulator.• Inspect(optionalHydra-Flex)motorstarterforcorrosion,ifidentifiedorderreplacement/spareparts.
1-3 Years• Inspectandreplaceinjectors.• Replacewatervalves.
Elbows/Pipe Fittings• Elbowsandotherpipefittingsaddbackpressurebycausingthefluidtochangedirectionand
thuschangingthefluid’smomentum.Trytofindsimplerwaystorouteyourfluidwithoutelbows.
© Hydra-Flex, Inc. 2017 Page | 11
PUMP ISSUES (IF USING OPTIONAL HYDRA-FLEX PUMP)TROUBLESHOOTING
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.
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.
Excessive Noise From Pump
Pumpnotsecuredfirmly Secureproperly.
Restrictedinlet Cleanorcorrectrestriction.
Waterregulatorfluttering/chattering
Trytoadjustregulatordownandthenbackuporreplaceregulator/removecheckvalves/pressureregulatorsfromH20feedtopump.
Cavitation(soundslikemarblesinpump) Increaseinletsize/inletpressure.
Wornmechanicalseal Replacepump.
Notprimed Re-primepump.
Pump LeaksLoosefittings,andornotenoughthreadtape
Tightenfittings,andortakepartoffandputnewthreadtapeon.
Failedseals Replacepump.
AIR OPERATED VALVE REPLACEMENT1. ShutofftheballvalvetoSDorHydra-Cannonmanifold.2. Disconnectairlinefromfrontofvalve.3. Unscrewquickconnectfittingbyhand(DO NOT LOSE BLACK WASHER).4. UnscrewvalveassemblyfromtheHydra-Cannonmanifold.5. Screwnewvalveintomanifolduntilhandtightandthreadedpilotportisfacingforward.6. Removethecapfrompilotportandthreadinquick
connectfittingtofrontofvalve–HAND TIGHT ONLY.7. Pushairlinebackintofitting.8. OpentheballvalvetotheHydra-Cannonmanifold.
Unscrew from manifold using this portion of valve
© Hydra-Flex, Inc. 2018 Page | 12
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 StrongHydro-FluoricAcid CallHydra-Flexandordercompositeversionofinjectors.
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.
FLOW / ARCH ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS
Flow At Arch Is Too Low
Incorrectinjectorflowrateselection
Replacewithlargerinjector
Systempressuretoolow Ensuresystempressureissetat200psi
Foamgeneratorplugged Ensurecleanedandclear
DownstreamplumbingrestrictiveIncreasesizeofplumbing/tubing,ensurecheckvalvesarecleanedornew,reduceelbowsinlineorotherturnsthatwouldrestrict
VALVE ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS
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.
© Hydra-Flex, Inc. 2017 Page | 13
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
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.
BACKGROUND:ThistoolisforinitialsetupandtroubleshootingofChem-Flex™InjectorsandanAqua-Lab™ChemicalDispensingSystem.Inorderfortheinjectortoworkproperlyanddrawchemicalthisgaugemustbeinthe“GREEN”sectionwheninstalledimmediatelyafteraninjectorthatisrunning.Ifthegaugeisintheredyouwilleithersee:intermittentchemical,nochemicaldraw,orchemicalbeingappliedataverylowpressure.
Backpressurereferstothepressureinthesolutionoutputline.Excessivebackpressureisthemainreasonthatinjectorswillnotdraw.Ifthereiseveranyconcerntowhyaninjectorisnotdrawingchemical,thebestandeasiestwaytodiagnosetheproblemistocheckthebackpressure.Seeinstructionsbelow:
INJECTOR OPTIMIZATION TOOL
Injector Optimization Tool Part Number: 1002018
© Hydra-Flex, Inc. 2018 Page | 14
APPENDIX: 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
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
1
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
4
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
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
7
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
48
#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
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
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
4
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
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
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
64
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
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
36
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
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
24
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
66
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
RED
1: 1
21:
17
1: 2
31:
34
1: 4
51:
46
1: 6
51:
69
1: 8
01:
95
1: 1
16
WH
ITE
1: 1
21:
16
1: 2
21:
31
1: 4
21:
43
1: 6
11:
64
1: 7
41:
88
1: 1
08
GRE
EN1:
11
1: 1
41:
20
1: 2
81:
37
1: 3
81:
53
1: 5
51:
65
1: 7
61:
94
BLU
E1:
10
1: 1
21:
17
1: 2
31:
30
1: 3
11:
44
1: 4
61:
53
1: 6
31:
77
YELL
OW
1: 9
1: 1
21:
16
1: 2
01:
22
1: 3
01:
31
1: 3
61:
42
1: 5
2
BLA
CK
1: 1
01:
13
1: 1
61:
17
1: 2
31:
24
1: 2
81:
33
1: 4
0
PURP
LE1:
6.6
1: 8
.31:
91:
10
1: 1
31:
13
1: 1
51:
17
1: 2
1
GRA
Y1:
5.3
1: 6
.71:
6.9
1: 7
.61:
9.9
1: 1
01:
11.
61:
13
1: 1
6
OPE
N1:
4.9
1: 5
.31:
5.2
1: 6
.01:
6.1
1: 6
.11:
7.6
1: 8
.31:
10
3/7”
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)
)
NO
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
.
Metering Tip
© Hydra-Flex, Inc. 2017 Page | 15
CHEM-FLEX INJECTOR PART NUMBERS
Max Pressure
Inlet
NPT up to 1000 PSI (69 bar)
PC2 Standard up to 500 PSI (34 bar)
PC2 Composite up to 250 PSI (17 bar)
Max Pressure Outlet
333 PSI (23 bar)Temperature Range 33°F - 140°F (.5°C - 60°C)
Maximum Wrench Torque Hand Tighten Only 30 ft-lbs
SPECIFICATIONS
INLET CONNECTION PC2 STANDARD (QUICK CONNECT) PC2 COMPOSITE (QUICK CONNECT)
OUTLET CONNECTION 3/8” MNPT 3/8” MNPT
FOR USE WITH AQUA-LAB MODEL(S) SD SD
COLOR FLOW RATE @ 200 PSI (14 bar) SINGLE BARB DUAL BARB SINGLE BARB DUAL BARB
White 0.25 GPM (1.0 LPM) 618029 - 718029 729029
Yellow 0.50 GPM (1.9 LPM) 618040 629040 718040 729040
Tan 0.75 GPM (2.8 LPM) 618051 629051 718051 729051
Red 1.00 GPM (3.8 LPM) 618057 629057 718057 729057
Orange 1.50 GPM (5.7 LPM) 618070 629070 718070 729070
Gray 2.00 GPM (7.6 LPM) 618083 629083 718083 729083
Dark Blue 2.25 GPM (8.5 LPM) 618086 629086 718086 729086
Light Blue 3.00 GPM (11.3 LPM) 618095 629095 718095 729095
Light Green 3.25 GPM (12.3 LPM) 618098 629098 718098 729098
Pink 3.75 GPM (14.2 LPM) 618106 629106 718106 729106
Purple 4.50 GPM (17.0 LPM) 618117 629117 718117 729117
Dark Green 5.50 GPM (20.8 LPM) 618125 629125 718125 729125
© Hydra-Flex, Inc. 2018 Page | 16
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 DarkBlue
LightBlue
Light Green Pink Purple Dark
Green
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” (2.41 mm)
0.098”(2.5 mm)
0.106” (2.69 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 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 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 LightBlue
LightGreen Pink Purple Dark
Green
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” (2.41 mm)
0.098”(2.5 mm)
0.106” (2.69 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 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 6 PSI 9 PSI
Run
Leng
th
1/2” ID BRAIDED
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 LightBlue
LightGreen Pink Purple Dark
Green
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” (2.41 mm)
0.098”(2.5 mm)
0.106” (2.69 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 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
© Hydra-Flex, Inc. 2017
NOT3T2T1
NOL3L2L1
A2A1
Contacter
95
T3T2T1
989796
ThermalOverload A21816
15B1A1
TimerRelay
CB
1/B
RN
CB
2/B
RN
TEM
P1
TEM
P2
CB
1/B
LU
CB
2/B
LU
CB
1/B
LK
CB
2/B
LK
2T1/
1
4T2/
1
6T3/
1
PE
1L1 3L2 5L3
2T1 4T2 6T3
CurrentSwitch
From BreakerFrom Grey M12 Cables
To Pump Through Power Fast Quick Connect
3 Phase
Disconect
V+
Valve
Sig
nal
V-
Jumper Jumper
JumperJumper
3 Phase
Control Voltage
Page | 17
(Port 6 on M12 Block)
(OPTIONAL HYDRA-FLEX MOTOR STARTER)WIRING DIAGRAM
SINGLE PUMP
© Hydra-Flex, Inc. 2018
1. FLUSHMakesurewatersupplytopumpisturnedon.Openballvalveanddirecttowardadrainorcontainertoremovethemajorityoftheairfromthepumpuntilasteadystreamofwaterisflowing(approx. 1 min).Thenclosetheballvalve.
2. CHECK ROTATION OpenAqua-Lab™MotorControlUnit(MCU)andensure3phasedisconnectison.(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).!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 ConnectthepumpoutletlinetotheHydra-CannonManifoldandopenballvalve.
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.
Page | 18
START UP (OPTIONAL HYDRA-FLEX PUMP)PUMP MUST BE PRIMED BEFORE OPERATION!WARNING!
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
Image 5
Image 6Image 7
© Hydra-Flex, Inc. 2017 Page | 19
GPM
PRES
SURE
AD
DED
(PSI
)
00
20
40
60
80
100
120
140
160
180
200
220
240
5 10 15 20 25 30 35 40
20 GPM Pum
p
10 GPM Pum
p
PUMP CURVES (HYDRA-FLEX PUMP)(CHART REPRESENTS MAXIMUM PUMP BOOSTED PRESSURE
AT VARIOUS FLOW RATES)
© Hydra-Flex, Inc. 2018
41
3
2
5
68
7
PART NAME PART NUMBER1 Air Actuated Hydra-Cannon Valve Replacement Kit - Composite 3000931
2 10-32” X 1/4” Push-To-Connect Air Fitting For Air Actuated Valve 3000987
3 Solenoid Actuated Air Valve - Non Foaming
24 VAC - 3001152
24 VDC - 3001153
120 VAC - 3001154
4 Outlet Pressure Gauge 0-300 PSI Bottom Mount 3000928
5 Single Gray Hydra-Cannon Replacement Assembly 1001777
6 Hydra-Cannon Interface Fitting Assembly - Black 1002040
7 Hydra-Cannon End Plug Assembly 3000561
8 SD Cross 3000935
AQUA-LAB™ - PANEL PARTS DIAGRAM & LIST
Page | 20
© Hydra-Flex, Inc. 2017
NUMBER PART NAME PART NUMBER9 (Not Shown) Ball Valve 1/2” - 3000565
10 (Not Shown) Manifold Inlet 1/2” ID Hose X 1/2” NPT Ends - 72” (1.8 M) Long 3000579
11 1” Male Quick Connect - Brass 3000205
12 1” Female Quick Connect - Brass 3000206
13 3/4” Male Quick Connect - Brass 3000196
14 3/4” Female Quick Connect - Brass 3000197
15 1” Wye Strainer - 30 Mesh 3000490
16 1” NPT T16 Wye Strainer Screen & Gasket Kit 1001938
17 1” NPT T15 Wye Strainer Screen & Gasket Kit 1001939
18 3/4” Wye Strainer - 20 Mesh 3000668
19 3/4” NPT T16 Wye Strainer Screen & Gasket Kit 1001936
20 3/4” NPT T15 Wye Strainer Screen & Gasket Kit 1001937
21 40 GPM (150 LPM) Bypass Pressure Regulator - Stainless Steel 3000464
22 20 GPM (75 LPM) Bypass Pressure Regulator - Brass 3000951
23 Quick Connect 9’ (3 M) Cordset For Booster Pump 3000782
24 Temperature Switch Assembly 1002313
25 Thermal Relief Valve - 1/2” NPT 3000323
26 20 GPM (75 LPM) Quick Connect Regulator Plumbing Assembly 1002340
38 Replacement/Backup 20 GPM (75 LPM) Booster Pump 1001362
39 (Not Shown) Booster Pump Floor Stand 1002250
40 Dual Booster Pump Wall Mount Bracket 3000921
41 (Not Shown) Triple Booster Pump Wall Mount Bracket 3000950
42 3/4” Air Actuated 3-Way Ball Valve Inlet Selector 3001165
43 Replacement/Backup 10 Gpm (38 Lpm) Booster Pump 1002285
23
40
29
38
11121516 or 17
24or 25
26
21
43
13
14
42
22
25
1819 or 20
AQUA-LAB™PUMP PARTS
DIAGRAM & LIST
Page | 21
© Hydra-Flex, Inc. 2018
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 - Sprecher & Shuh 3000862
46 Thermal Overload - Eaton 1002757
47 Timer Relay 1002758
49 Current Sensor - AC 3000666
50 Current Sensor - DC 3000866
51 Contactor - Eaton
24 VAC - 3001336
24 VDC - 3001337
120 VAC - 3001338
52 Contactor - Sprecher & Shuh
24 VAC - 3000863
24 VDC - 3000864
120 VAC - 3000865
49 or 5045 47 46 46 51
47
52
47
49 or 50
46
SPRECHER & SCHUH EATON
AQUA-LAB™ - MCU PARTS DIAGRAM & LIST
Page | 22
© Hydra-Flex, Inc. 2017 Page | 23
PART NAME PART NUMBERDuo-Foam Kit 1001869
Triple-Foam Kit 1001948
Anti-Siphon Kit (PC2) 1001436
Injector Optimization Tool 1002018
Vacuum Tester kit 1001104
Water Filtration System - Cold 1001431
Water Filtration System - Cold - Replacement Filter Cartridge 3000855
PC2 Plug 3000022
Flow-Thru Adapter 3000173
Stainless Steel Motor Drip Shield (Wall Mounted Booster Pumps Only) 3001347
Vinyl Hose Barb Cap 3000745
Remote Metering Device/Check Hub 1001756
3/8” Coupler 3000522
3/8” Elbow 3000523
3/8” x 1/2” Push-To-Connect 3000526
3/8” Check Valve (PC2) 3000970
AQUA-LAB™ - ACCESSORIES
© Hydra-Flex, Inc. 2018
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 SD™ WARRANTY
Page | 24
T:952-808-3640•F:952-808-3650•www.hydraflexinc.com•[email protected]
4000061 revG0518