IMPROVED PERFORMANCE – With flow capacity of up to 15 GPM per valve (up to 45 GPM per manifold), the Aqua-Lab HD was developed to meet the demands of high-volume tunnel wash applications such as foam curtains, rain bars, truck, bus, and train wash systems.

DURABLE & RELIABLE CONSTRUCTION – An inert, chemically resistant Kynar® manifold with integrated, reliable air-actuated valves offer enhanced dependability over electric solenoid valves.

INTUITIVE DESIGN – New features include vertical valve orientation for clean plumbing management, a hinged panel for easy access to air regulators, and a small injector/tip storage tray.

MODULAR & CONFIGURABLE – Select from 3, 5, or 7 high-flow valve positions (HD) or combine (2) high and (5) medium-flow valves on one panel (XD). Several new accessories are also available to customize to your unique equipment configuration.

AQUA-LAB™ HD & XDHIGH-FLOW CHEMICAL DISPENSING SYSTEM

www.hydraflexinc.com

2016 NEWPRODUCTS

HIGH-FLOW CHEMICAL DISPENSING SYSTEM

Valve Cage

Plunger

Spring

End Cap

Hinged panel for easy access to air regulators

PC3 Quick Connect, all composite injectors -

available in 8, 10, 12, and 15 GPM.

Inert, chemically resistant Kynar® manifold

(3, 5, or 7 positions)

Air regulators aligned with valve position

Optional Rack Mounting Kit

Reliable, integrated air actuated valve

Small tray for quick storage of injectors and metering tips

Chemically inert composite nozzle & body

Barb Fitting

XFC o-ring for increased chemical resistance to reduce o-ring swelling

Teflon® check ball

Hastelloy® spring

Vertical valve orientation for clean plumbing management

CUSTOMIZE YOUR SYSTEM

Choose one or a combination of panels based on the total number of arches/applications and flow requirements in your car wash. Each panel is delivered pre-wired and plumbed for water, air, and chemical control.

STEP 1: PICK YOUR PANEL(S)

AQUA-LAB HD3/5

AQUA-LAB HD5/7

AQUA-LAB HD7/9

AQUA-LAB XD5/2/9

Manifold panel for up to (3) applications (up to 15 GPM each valve or 45 GPM total.)

INCLUDES:(3) High-Flow, Integrated Air-Actuated Water Valves (3) Air Valves (3) or (5*) Foaming Air Regulators

Manifold panel for up to (5) applications (up to 15 GPM each valve or 45 GPM total.)

INCLUDES:(5) High-Flow, Integrated Air-Actuated Water Valves (5) Air Valves (5) or (7*) Foaming Air Regulators

Manifold panel for up to (7) applications (up to 15 GPM each valve or 45 GPM total.)

INCLUDES:(7) High-Flow, Integrated Air-Actuated Water Valves (7) Air Valves (7) or (9*) Foaming Air Regulators

Manifold panel for up to (7) applications. Combination of (5) standard-flow valves (up to 6 GPM each or 18 GPM total) and (2) high-flow valves (up to 15 GPM each or 30 GPM total). Includes:

(5) Stainless steel Air-Actuated Water Valves (2) High-Flow Integrated Air-Actuated Water Valves (7) Air Valves (7) or (9*) Foaming Air Regulators

PANEL VOLTAGE PART NUMBERXD5/2/7 24 VAC 1002210

XD5/2/7 24 VDC 1002211

XD5/2/7 120 VAC 1002212

XD5/2/9* 24 VAC 1002213

XD5/2/9* 24 VDC 1002214

XD5/2/9* 120 VAC 1002215

* Intended for use with a Tri-Foam Kit (sold separately)

PANEL VOLTAGE PART NUMBERHD7/7 24 VAC 1002204

HD7/7 24 VDC 1002205

HD7/7 120 VAC 1002206

HD7/9* 24 VAC 1002207

HD7/9* 24 VDC 1002208

HD7/9* 120 VAC 1002209

* Intended for use with a Tri-Foam Kit (sold separately)

PANEL VOLTAGE PART NUMBERHD5/5 24 VAC 1002198

HD5/5 24 VDC 1002199

HD5/5 120 VAC 1002200

HD5/7* 24 VAC 1002201

HD5/7* 24 VDC 1002202

HD5/7* 120 VAC 1002203

* Intended for use with a Tri-Foam Kit (sold separately)

PANEL VOLTAGE PART NUMBERHD3/3 24 VAC 1002192

HD3/3 24 VDC 1002193

HD3/3 120 VAC 1002194

HD3/5* 24 VAC 1002195

HD3/5* 24 VDC 1002196

HD3/5* 120 VAC 1002197

* Intended for use with a Tri-Foam Kit (sold separately)

New vertical centrifugal multistage pumps with VFD controls offer enhanced efficiency and reliability. See Vehicle Wash Catalog, Vol. 2, pages 6-8 for a complete listing of pump options.

STEPS 2 & 3: PICK YOUR PUMP & MOTOR CONTROL SYSTEM

LARGER FLOW CAPACITY – Upgrade to Grundfos vertical multistage centrifugal pump systems with either 20 GPM (5 HP) or 40 GPM (7.5 HP) flow capacities.

LONGER LIFE & LESS MAINTENANCE – Grundfos pumps are equipped with stainless steel impellers, TEFC (totally enclosed fan cooled) motors, and higher temperature thresholds for longer life and less maintenance. Grundfos pump systems are also rebuildable (rebuildable stack, replaceable motor with bearing) for lower lifetime operating costs.

FULLY INTEGRATED SYSTEMS – Grundfos pump systems include VFD motor controls, a pressure transducer for pressure and flow control, inlet and outlet plumbing connections for up to 3 panels, wye strainer, and 8 ft. power cord with flying leads.

EFFICIENT – Because a VFD adjusts the speed of the motor based on real-time site demands and system flow requirements, it can reduce related energy consumption and costs.

EXTENDS THE LIFE OF THE PUMP – Puts less wear and tear on the motor and results in cooler running pumps due to water not bypassing.

IMPROVED CHEMICAL CONSISTENCY – Tighter tolerances on a VFD eliminate pressure fluctuations that may vary by +/- 10-15 PSI on a standard water pressure regulator.

POTENTIAL LOCAL UTILITY REBATES – The federal government and many local utilities offer incentives and rebates when installing energy efficient devices like VFDs. Contact your local utility or check the national database at www.dsireusa.org.

GRUNDFOS PUMP SYSTEM

VARIABLE FREQUENCY DRIVE (VFD)

*Other voltage options may be available. Contact Hydra-Flex for more information.

*Customer must supply own Motor Control Unit.

PUMP SYSTEM & VFD MCU

SITE VOLTAGE*

CONTROL VOLTAGE

PART NUMBER

20 GPM (75 LPM)5 HP Pump w/ VFD 230V 24 or 120 VAC 1002115

20 GPM (75 LPM)5 HP Pump w/ VFD 230V 24 VDC 1002116

20 GPM (75 LPM)5 HP Pump w/ VFD 460V 24 or 120 VAC 1002113

20 GPM (75 LPM)5 HP Pump w/ VFD 460V 24 VDC 1002114

40 GPM (150 LPM)7.5 HP Pump w/ VFD 230V 24 or 120 VAC 1002123

40 GPM (150 LPM)7.5 HP Pump w/ VFD 230V 24 VDC 1002124

40 GPM (150 LPM)7.5 HP Pump w/ VFD 460V 24 or 120 VAC 1002121

40 GPM (150 LPM)7.5 HP Pump w/ VFD 460V 24 VDC 1002122

PUMP ONLY (NO MCU)*

SITE VOLTAGE

CONTROL VOLTAGE

PART NUMBER

20 GPM (75 LPM)5 HP Pump 230V - 1002148

20 GPM (75 LPM)5 HP Pump 460V - 1002147

40 GPM (150 LPM)7.5 HP Pump 230V - 1002150

40 GPM (150 LPM)7.5 HP Pump 460V - 1002149

OPTIONAL ACCESSORIES PART NUMBERProtective Kick Plate Cover, Floor-Mount (pro-

tects the pump, plumbing, and pressure transducer against accidental damage).

1002159

CUSTOMIZE YOUR SYSTEM

Accessories are available to customize Aqua-Lab to your unique equipment configuration. See Vehicle Wash Catalog, Vol. 2, pages 16-19 for other accessory options.

STEP 4: PICK YOUR ACCESSORIES

EASY TO INSTALL – Simply slide the racks into place – no wall mounting required. (Floor securing hardware is included.) The rack mounting kit holds any size Aqua-Lab panel with booster pump, motor controls, and basic tubing management. Systems are delivered pre-wired and pre-plumbed for water, air, and chemical control.

IDEAL FOR RETROFITS – Don’t lose revenue by shutting down to make upgrades. The rack mount kit allows live changeover from legacy equipment, and its streamlined, compact design takes up less overall wall space.

CONFIGURABLE – Install racks in line for a centralized chemical control station or space them out to strategically optimize your back room. A stainless steel work tray is also available as an optional accessory.

FAST APPLICATION – The Bug Prep Kit converts 1 port on your Aqua-Lab into a gun-operated hand-prep system for applying foamed solution – fast.

FOAMING PREP GUN – Gun with built-in foam generator maximizes your solution’s foaming, cleaning, and cling ability. Longer working length (30 ft.) of durable Polyflow hose runs air and solution to the gun simultaneously and is coiled for easy retraction and operation.

IMPROVED RELIABILITY – New and improved features include a gauge isolator to prevent chemical attack on the pressure switch, a large dead-band on the pressure switch reduces unwanted air valve chatter, and a high-temperature shutdown box protects your pumps in the event of a plumbing leak.

AQUA-LAB RACK MOUNTING KIT

BUG PREP KIT

AQUA-LAB SYSTEMS USED IN PART NUMBERMotor Control Unit Mounted Rack (Shown)

MD/HD/XD 1002090

Variable Frequency Device Mounted Rack

MD/HD/XD 1002146

Optional Stainless Steel Tray

MD/HD/XD 1002080

Optional Pre-Wire Electrical Kit

MD/HD/XD230V - 1002309

460V - 1002308

SPACE REQUIREMENTS(DEPTH x WIDTH x HEIGHT)

34” x 35” x 71” (This is the maximum space required with all

options and components)

DESCRIPTION PART NUMBERBug Prep Kit For New Systems 1002258

Bug Prep Kit For Retrofits (For Use With MCU’s Without High Temperature Shutdown) 1002256

CUSTOMIZE YOUR SYSTEM

CUSTOMIZE YOUR SYSTEM

DUO-FOAM KIT (HD/XD)

Two position quick-connect manifold that fits into a single Aqua-Lab port for dispensing two chemicals or colors to the same applicator. Includes (1) duo-foam manifold, (2) check valves, and (2) ½” poly push-connect fittings. For use with PC2 injectors (not included.)

For use with foam curtain applicators that use two foam generators. Requires one port on an Aqua-Lab system and 6.5 GPM of pump capacity. Kit includes (1) duo-foam manifold, (2) check valves, (2) ½” poly push-connect fittings, (2) anti-siphon devices, (2) .098 light green injectors and (2) packs of standard metering tips.

Three position quick-connect manifold that fits into a single Aqua-Lab port for dispensing three chemicals or colors to the same applicator. Includes (1) triple-foam manifold, (3) check valves, and (3) ½” poly push-connect fittings. For use with PC2 injectors (not included.)

For use with foam curtain applicators that use three foam generators. Requires one port on an Aqua-Lab system and 6.75 GPM of pump capacity. Kit includes (1) triple-foam manifold, (3) check valves, (3) ½” poly push-connect fittings, (3) anti-siphon devices, (3) .086 blue injectors and (3) packs of standard metering tips.

Anti-siphon kit reduces the effects of water hammer. Pre-vents drawing concentrated chemical into your solution line when the valve is closed. (Includes 1 piece.)

AQUA-LAB SYSTEM USED IN

PART NUMBER

HD/XD 1002266

AQUA-LAB SYSTEM USED IN

PART NUMBER

HD/XD 1002267

AQUA-LAB SYSTEM USED IN

PART NUMBER

HD/XD 1002224

AQUA-LAB SYSTEM USED IN

PART NUMBER

HD/XD 1002268

AQUA-LAB SYSTEM USED IN

PART NUMBER

HD/XD 1002230

DUO-FOAM KIT FOR FOAM CURTAIN APPLICATIONS (HD/XD)

TRIPLE FOAM KIT (HD/XD)

TRIPLE-FOAM KIT FOR FOAM CURTAIN APPLICATIONS (HD/XD)

ANTI-SIPHON KIT (HD/XD)

CUSTOMIZE YOUR SYSTEM

DISTRIBUTION MANIFOLD (HD/XD)

Allows you to split one large chemical line (3/4” NPT inlet) into (3) or (4) smaller lines (1/2” OD poly flow outlets) at the arch. Includes (1) 3/8” NPT plug & hose clamp for 3/4” ID inlet.

Allows you to adapt a high-flow PC3 valve to be used with any PC2 Chem-Flex injector.

AQUA-LAB SYSTEM USED IN

PART NUMBER

HD/XD 1002289

AQUA-LAB SYSTEM USED IN

PART NUMBER

HD/XD 1002094

PC3 TO PC2 ADAPTER (HD/XD)

SYSTEM REQUIREMENTS/SPECIFICATIONS

Power Requirements40 GPM (150 LPM) 7.5 HP Grundfos Pump Air-Actuated Valves

230V/3PH/60Hz/18.6A* or 460V/3PH/60Hz/8.9A 24VAC, 24VDC, or 120VAC, 3.5 Watts per port

Space Requirements40 GPM Grundfos VFD MCU HD/XD Panels

19” x 15” x 42” 14” x 21” x 20” 7” x 32” x 34”

Water Inlet Line 2” ID (40 GPM Grundfos Pump)

Operating Water Pressure 200 PSI (14 bar) (Factory Set) Assuming 40 PSI (2.8 bar) City Feed

Max. Water Source Temperature 137ºF (+58ºC)

Air Inlet Line 3/8” OD Polyflow Per Panel

Air Outlet Line 3/8” OD Polyflow Per Application

Air Inlet Pressure 20 CFM @ 80-120 PSI (0.6 cubic meter/minute @ 5.5 - 8.3 bar) Dry Air

Solution Outlet Lines**Up 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

*Recommended for use with 30A breaker.

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

PC3 INJECTOR DILUTION RATIO CHART(Assumes feed pressure of 200 PSI (14 bar))

THE MOST CHEMICAL-RESISTANT INJECTOR ON THE MARKET – Hydra-Flex has developed an innovative solution that will stand up to the most aggressive, yet common car wash chemicals – the composite PC3 injector. The nozzle and body of these injectors are manufactured using a corrosion-resistant composite material, which has been tested by the industry’s leading chemical manufacturers with consistently positive results. A Hastelloy spring, a Teflon check ball, and an exclusive XFC o-ring material are also used for long life and durability.

HIGHER FLOW CAPABILITY – NEW PC3 Chem-Flex injectors are available in flows of 8, 10, 12, and 15 GPM.

PC3 INJECTOR PART NUMBERSCOLOR FLOW

ORIFICEFLOW RATE @

200 PSI (14 bar)SINGLE BARB

Black 0.161 (4.09 mm) 8.0 GPM 818161

Black 0.177 (4.50 mm) 10.0 GPM 818177

Black 0.186 (4.72 mm) 12.0 GPM 818186

Black 0.207 (5.26 mm) 15.0 GPM 818207

#8-32 METERING TIPS

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

Injector Color Black Black Black Black

Nozzle Size 0.161” (4.09 mm)

0.177” (4.50 mm)

0.186” (4.72 mm)

0.207” (5.26 mm)

COPPER 1: 2019 1: 2318 1: 3324 1: 4259

PUMPKIN 1: 1465 1: 1832 1: 2310 1: 3042

BURGUNDY 1: 1244 1: 1670 1: 1975 1: 2469

LIME 1: 988 1: 1262 1: 1481 1: 1958

TAN 1: 826 1: 1042 1: 1286 1: 1577

ORANGE 1: 7.51 1: 874 1: 1136 1: 1262

TURQUOISE 1: 561 1: 752 1: 885 1: 1099

PINK 1: 372 1: 473 1: 570 1: 728

LIGHT BLUE 1: 318 1: 406 1: 483 1: 572

BROWN 1: 270 1: 338 1: 408 1: 507

RED 1: 202 1: 254 1: 306 1: 375

WHITE 1: 180 1: 226 1: 272 1: 343

GREEN 1: 160 1: 201 1: 241 1: 300

BLUE 1: 122 1: 152 1: 185 1: 224

YELLOW 1: 80 1: 100 1: 120 1: 148

BLACK 1: 61 1: 77 1: 92 1: 115

PURPLE 1: 31 1: 39 1: 46 1: 57

GRAY 1: 24 1: 30 1: 35 1: 44

OPEN 1: 12 1: 15 1: 18 1: 23

Met

erin

g Ti

p

NEW PC3 injectors combine with chemical metering tips to proportion the precise chemical mix ratio. See Vehicle Wash Catalog, Vol. 2, pages 29-32 for more injector options.

STEP 5: PICK YOUR CHEMICAL INJECTORS

PC3 CHEM-FLEX™ CHEMICAL INJECTORS

NOTE: Dilution ratios given are based on drawing water through the metering tips and are meant as a starting point for system configuration. Results are expected to vary when drawing chemicals due to differences in viscosity and temperature. There may be slight variations of performance in injectors and metering tips that are unavoidable due to manufacture tolerances. Using the same tip color from site to site is a good starting point. However with the potential for variation from part to part it is reasonable to still need to do some adjustments from there.

T: 952-808-3640 • F: 952-808-3650 • www.hydraflexinc.com • sales@hydraflexinc.com

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